1998 Ford Econoline E350 6.3 L Fuel System Diagram
Factory Workshop Manual Make Ford Model Econoline E350 1 Ton Engine and year V10-6.8L VIN S (1998) 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 Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 ( P 0705 ) P0705 - P0709: Testing and Inspection P0705 ( P 0705 ) E4OD For diagnosis of P0705 refer to chart Part 4 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 ( P 0705 ) > Page 9 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 ( P 0705 ) > Page 10 P0705 - P0709: Testing and Inspection P0708 ( P 0708 ) E4OD For diagnosis of P0708 refer to chart Part 4 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 ( P 0705 ) > Page 11 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 ( P 0712 ) P0710 - P0714: Testing and Inspection P0712 ( P 0712 ) E4OD For diagnosis of P0712 refer to chart Part 3 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 ( P 0712 ) > Page 16 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 ( P 0712 ) > Page 17 P0710 - P0714: Testing and Inspection P0713 ( P 0713 ) E4OD For diagnosis of P0713 refer to chart Part 2 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > P0715 ( P 0715 ) P0715 - P0719: Testing and Inspection P0715 ( P 0715 ) For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > P0715 ( P 0715 ) > Page 22 P0715 - P0719: Testing and Inspection P0717 ( P 0717 ) For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > P0715 ( P 0715 ) > Page 23 P0715 - P0719: Testing and Inspection P0718 ( P 0718 ) For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 ( P 0731 ) P0730 - P0734: Testing and Inspection P0731 ( P 0731 ) For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 ( P 0731 ) > Page 28 P0730 - P0734: Testing and Inspection P0732 ( P 0732 ) For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 ( P 0741 ) P0740 - P0744: Testing and Inspection P0741 ( P 0741 ) E4OD For diagnosis of P0741 refer to chart Part 6 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 ( P 0741 ) > Page 33 P0740 - P0744: Testing and Inspection P0743 ( P 0743 ) E4OD For diagnosis of P0743 refer to chart Part 5 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > 4R100 P0750 - P0754: Testing and Inspection 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > 4R100 P0755 - P0759: Testing and Inspection 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 ( P 0781 ) P0780 - P0784: Testing and Inspection P0781 ( P 0781 ) E4OD For diagnosis of P0781 refer to chart Part 2 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 ( P 0781 ) > Page 46 P0780 - P0784: Testing and Inspection P0782 ( P 0782 ) For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 ( P 0781 ) > Page 47 P0780 - P0784: Testing and Inspection P0783 ( P 0783 ) E4OD For diagnosis of P0783 refer to chart Part 4 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 ( P 0781 ) > Page 48 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1704 P1700 - P1704: Testing and Inspection P1704 E4OD For diagnosis of P1704 refer to chart Part 6 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1713 P1710 - P1714: Testing and Inspection P1713 E4OD For diagnosis of P1713 refer to chart Part 6 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1713 > Page 58 P1710 - P1714: Testing and Inspection P1714 E4OD For diagnosis of P1714 refer to chart Part 5 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 P1715 - P1719: Testing and Inspection P1715 E4OD For diagnosis of P1715 refer to chart Part 5 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 63 P1715 - P1719: Testing and Inspection P1718 E4OD For diagnosis of P1718 refer to chart Part 6 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729, ( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis > P1728 P1725 - P1729: Testing and Inspection P1728 E4OD For diagnosis of P1728 refer to chart Part 3 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729, ( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis > P1728 > Page 68 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > 4R100 P1740 - P1744: Testing and Inspection 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 P1745 - P1749: Testing and Inspection P1746 E4OD For diagnosis of P1746 refer to chart Part 6 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 77 P1745 - P1749: Testing and Inspection P1747 E4OD For diagnosis of P1747 refer to chart Part 6 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1750 - P1754, ( P1751 P1752 P1753 1750 1751 1752 1753 1754 ) > System Information > System Diagnosis > 4R100 P1750 - P1754: Testing and Inspection 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1783 P1780 - P1784: Testing and Inspection P1783 E4OD For diagnosis of P1783 refer to chart Part 4 - 6 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1783 > Page 86 4R100 For later model 1998 vehicles with the 4R100 transmission please refer to the 1999 model year for testing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: Customer Interest Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 97 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 98 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: All Technical Service Bulletins Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 104 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 105 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 106 Keyless Entry Module: Locations Full Body Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 107 The Remote Keyless Entry (RKE) module with integral receiver is located behind the B-pillar on the driver side. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 108 Keyless Entry Module: Diagrams Remote Keyless Entry Module (C335) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 109 Remote Keyless Entry Module (C336) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 110 Keyless Entry Module: Description and Operation The Remote Keyless Entry (RKE) module performs the following functions: - Unlocks the driver front door. - Unlocks all doors. - Locks all doors. - Turns on the interior lamps after either front door handle is lifted. - Turns on the interior lamps when using a keyless entry remote transmitter. - Activates and deactivates a personal security panic alarm feature that sounds the horn and flashes the parking lamps and headlamps. - Activates the lock verify feature that sounds the horn when the lock button is pressed on the keyless entry remote transmitter twice within five seconds. - Remembers to lock the sliding door if the door locks are activated when the sliding door is open. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Programming Procedure Keyless Entry Module: Service and Repair Programming Procedure Programming - Keyless Entry Remote Transmitter NOTE: To program (or reprogram) a keyless entry remote transmitter into the Remote Keyless Entry (RKE) module, perform the following steps: 1. Turn the key to the RUN or ACC position and short the two terminals of the program connector, a two-pin connector located at the base of the steering column connected to the ignition switch wiring harness. All doors should lock and then unlock. 2. Press any button on each keyless entry remote transmitter in turn. All doors should lock and then unlock. If the door locks do not respond, press the button again (up to three times maximum with the same keyless entry remote transmitter). 3. Repeat Step 2 to program additional keyless entry remote transmitters into the RKE module (up to four keyless entry remote transmitters maximum). 4. Turn the key off. 5. Remove the short from the program connector. All doors should lock and then unlock. 6. Verify that the keyless entry remote transmitters have been successfully programmed by pressing the lock or unlock button on each one, and observing that the system responds by locking and unlocking the doors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Programming Procedure > Page 113 Keyless Entry Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the body side trim finish panel. 1 Remove the three finish panel pushpins. 2 Remove the finish panel from the body side. 3. Remove the remote keyless entry module. 1 Disconnect the electrical connectors. 2 Remove the two nuts. 3 Remove the module. INSTALLATION 1. To install, reverse the removal procedure. - If installing a new module it is necessary to reprogram Remote Keyless Entry Transmitters. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: Customer Interest Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 123 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 124 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: All Technical Service Bulletins Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 130 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 131 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 132 Keyless Entry Module: Locations Full Body Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 133 The Remote Keyless Entry (RKE) module with integral receiver is located behind the B-pillar on the driver side. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 134 Keyless Entry Module: Diagrams Remote Keyless Entry Module (C335) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 135 Remote Keyless Entry Module (C336) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 136 Keyless Entry Module: Description and Operation The Remote Keyless Entry (RKE) module performs the following functions: - Unlocks the driver front door. - Unlocks all doors. - Locks all doors. - Turns on the interior lamps after either front door handle is lifted. - Turns on the interior lamps when using a keyless entry remote transmitter. - Activates and deactivates a personal security panic alarm feature that sounds the horn and flashes the parking lamps and headlamps. - Activates the lock verify feature that sounds the horn when the lock button is pressed on the keyless entry remote transmitter twice within five seconds. - Remembers to lock the sliding door if the door locks are activated when the sliding door is open. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Programming Procedure Keyless Entry Module: Service and Repair Programming Procedure Programming - Keyless Entry Remote Transmitter NOTE: To program (or reprogram) a keyless entry remote transmitter into the Remote Keyless Entry (RKE) module, perform the following steps: 1. Turn the key to the RUN or ACC position and short the two terminals of the program connector, a two-pin connector located at the base of the steering column connected to the ignition switch wiring harness. All doors should lock and then unlock. 2. Press any button on each keyless entry remote transmitter in turn. All doors should lock and then unlock. If the door locks do not respond, press the button again (up to three times maximum with the same keyless entry remote transmitter). 3. Repeat Step 2 to program additional keyless entry remote transmitters into the RKE module (up to four keyless entry remote transmitters maximum). 4. Turn the key off. 5. Remove the short from the program connector. All doors should lock and then unlock. 6. Verify that the keyless entry remote transmitters have been successfully programmed by pressing the lock or unlock button on each one, and observing that the system responds by locking and unlocking the doors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Programming Procedure > Page 139 Keyless Entry Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the body side trim finish panel. 1 Remove the three finish panel pushpins. 2 Remove the finish panel from the body side. 3. Remove the remote keyless entry module. 1 Disconnect the electrical connectors. 2 Remove the two nuts. 3 Remove the module. INSTALLATION 1. To install, reverse the removal procedure. - If installing a new module it is necessary to reprogram Remote Keyless Entry Transmitters. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Full Body Views The Memory Lock Module is located behind LH "B" pillar. NOTE: Systems without memory lock option do not use a door lock relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 143 Memory Lock Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Instrument Panel Views The 4 Wheel Anti-Lock Brakes Relay is located behind the center of instrument panel, on 4 wheel anti-lock brakes relay. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 148 4 Wheel Anti_Lock Brake System Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Rear Anti-Lock Brakes Electronic Brake Control Module: Specifications Rear Anti-Lock Brakes TORQUE SPECIFICATIONS Anti-Lock Brake Control Module Screws .................................................................................................................................. 2-3 Nm (17-26 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Rear Anti-Lock Brakes > Page 153 Electronic Brake Control Module: Specifications 4-Wheel Anti-Lock Brakes TORQUE SPECIFICATIONS Anti-Lock Brake Control Module Screws ................................................................................................................................................. .................................. 4-5 Nm (36-44 inch lbs.) To Bracket Bolts ........................................................ .......................................................................................................... 30-40 Nm (22-29 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Rear Antilock Brake (RABS) Module Electronic Brake Control Module: Locations Rear Antilock Brake (RABS) Module Instrument Panel Views The Rear Anti-Lock Brake System Module is located behind center side of the instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Rear Antilock Brake (RABS) Module > Page 156 Electronic Brake Control Module: Locations 4 Wheel Anti-Lock Brake System Module Engine Compartment Views The 4 Wheel Anti-Lock Brakes Module is located on the LH front frame rail. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Four Wheel Antilock Brakes 4 Wheel Anti_Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Four Wheel Antilock Brakes > Page 159 Rear Anti_Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) Electronic Brake Control Module: Service and Repair Four Wheel Anti-Lock Brake System (4WABS) REMOVAL 1. Remove the electronic hydraulic control unit (EHCU). 2. Detach the bracket from the EHCU. 1 Remove the bolts. 2 Detach the bracket from the EHCU. 3. Remove the anti-lock brake control module. 1 Remove the screws. 2 Remove the anti-lock brake control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 162 Electronic Brake Control Module: Service and Repair Rear Antilock Brake System (RABS) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the engine cover. 3. Remove the anti-lock brake control module. 1 Remove the screw. 2 Lower the module assembly. 3 Remove the nuts. 4 Disconnect the electrical connector. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 163 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to driven 16 km ( 10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams Speed Control Sensor/Amplifier Assembly Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Specifications Blower Motor Relay: Specifications Auxiliary Blower Motor Relay ............................................................................................................... ....................................................... ISO-Type Relay Auxiliary High-Speed Blower Motor Relay .................................................................................................................................................. ISO-Type Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay Blower Motor Relay: Locations Auxiliary Blower Relay Full Body Views The Auxiliary Blower Motor Relay is located at the left rear corner of the vehicle, above wheel well. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay > Page 174 Blower Motor Relay: Locations Auxiliary High Blower Motor Relay Full Body Views The Auxiliary High Blower Motor Relay is located at the left rear corner of the vehicle, above wheel well. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay > Page 175 Blower Motor Relay: Locations Blower Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay > Page 176 Engine Compartment Fuse Box (Part 2 Of 2) The Blower Motor Relay is located at the LH front of the engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay Blower Motor Relay: Diagrams Auxiliary Blower Motor Relay Auxiliary Blower Motor Relay (C403) Auxiliary Blower Motor Relay (C404) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay > Page 179 Blower Motor Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations Audible Warning Device Control Module: Locations Instrument Panel Views The Warning Buzzer Module is located behind the centre of instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations > Page 184 Warning Buzzer Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair > Warning Buzzer Module (RV Only) Audible Warning Device Control Module: Service and Repair Warning Buzzer Module (RV Only) REMOVAL 1. Disconnect battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the engine cover. 3. Remove the warning buzzer module. 1 Rotate the buzzer module 90 degrees. 2 Pull the buzzer away from the bracket. 3 Disconnect the electrical connector from the buzzer and remove the buzzer module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair > Warning Buzzer Module (RV Only) > Page 187 Audible Warning Device Control Module: Service and Repair Warning Chime Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the engine cover. 3. Remove the warning chime module. 1 Slide the chime module off the bracket. 2 Disconnect the electrical connector and remove the chime module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Testing and Inspection Speedometer Module: Testing and Inspection For Testing of this and other gauges, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Panel, Testing and Inspection. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications Daytime Running Lamp Control Module Bolts ........................................................................................................................... Nm (2.6-3.2 23-28 Lb-In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 195 Daytime Running Lamp Control Unit: Locations Engine Compartment Views The Daytime Running Lamps Module is located at the RH front of engine, near horns. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 196 Daytime Running Lamps Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 197 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Remove the A/C condenser air deflector. 1 Remove the six pushpins. 2 Remove the A/C condenser air deflector. 2. Remove the Daytime Running Lamps (DRL) control module. 1 Remove the bolts. 2 Disconnect the DRL control module connector 3 Remove the DRL control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations The Horn Relay is located in the Engine Compartment Fuse Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 201 Horn Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 202 Horn Relay: Testing and Inspection NOTE: Use three No. 10 (or larger gauge) jumper wires and 73 Digital Multimeter to test the horn relay. 1. Remove the relay from the power distribution box. 2. Using a multimeter, measure the resistance between Terminal 85 and all other terminals. If the resistance is 5 ohms or less, replace the relay. If the resistance is greater than 5 ohms, continue the test. 3. Use two jumper wires to connect Terminals 86 and 30 directly to the positive battery terminal. 4. Set the 73 digital multimeter in the volts position and check for voltage at Terminal 87 A. If battery voltage is not indicated, replace the relay. 5. If battery voltage is indicated, connect the third jumper wire to Terminal 85 and a known good ground. Check for voltage at Terminal 87. If battery voltage is not indicated, replace the relay. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations Interior Lighting Module: Locations Instrument Panel Views The Illuminated Entry Module is located behind the LH side of the instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 206 Illuminated Entry Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 207 Interior Lighting Module: Description and Operation Interior Lighting Components Illuminated Entry Module The illuminated entry module activates the interior lamps anytime the door handle is pulled to the open position. The length of time the illuminated entry system is energized is controlled by the illuminated entry module. The illuminated entry feature will be canceled when any of the following conditions are met: 25 seconds have elapsed since the illuminated entry feature was activated and the interior lamp control is turned off. - The ignition is in the RUN or START position, and the interior lamp control is not activated. On vehicles equipped with an optional remote keyless entry system, the functions of the illuminated entry module are performed by the Remote Keyless Entry (RKE) module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 208 Interior Lighting Module: Service and Repair REMOVAL CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damages may result. 1. Disconnect the battery ground cable. 2. Remove the engine cover. 3. Remove the illuminated entry module. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the illuminated entry module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations The trailer lamp relays are located in the Engine Compartment Fuse Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay Trailer Backup Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 214 Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 215 Trailer Running Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay Power Distribution Relay: Locations Auxiliary Battery Relay The Auxiliary Battery Relay is located at the right front of the engine compartment, near battery Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 221 Power Distribution Relay: Locations Trailer Backup Lamp Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 222 Engine Compartment Fuse Box (Part 2 Of 2) The Trailer Backup Lamp Relay is located at the LH front of engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 223 Power Distribution Relay: Locations Trailer Battery Charge Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 224 Engine Compartment Fuse Box (Part 2 Of 2) The Trailer Battery Charge Relay is located at the LH front of engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 225 Power Distribution Relay: Locations Trailer Running Lamp Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 226 Engine Compartment Fuse Box (Part 2 Of 2) The Trailer Running Lamp Relay is located at the LH front of engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Running Lamp Relay Trailer Running Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Running Lamp Relay > Page 229 Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Running Lamp Relay > Page 230 Trailer Backup Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 237 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Engine Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 242 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 243 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 244 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 245 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 246 Engine Control Module: Locations Engine Compartment Views The Powertrain Control Module is located at the left rear of the engine compartment, near brake master cylinder. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Engine Control Module: Connector Views Powertrain Control Module (Part 1 Of 2) 6.8 L E350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Powertrain Control Module (Part 2 Of 2) 6.8 L E350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Powertrain Control Modules (PCMs) are reprogrammable to update calibration levels without having to replace the PCM. The reprogramming may be performed with the PCM installed in the vehicle using the Service Bay Technical System (SBTS). The PCM may also be reprogrammed outside of the vehicle using the New Generation STAR (NGS) and a 15- to 104- Pin Flash Cable (007-00587 or equivalent). The Flash Cable connects between the NGS and the PCM. The proper calibration must be downloaded to the Data Transfer Card through the SBTS. Follow the download instructions displayed on the NGS screen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 260 Engine Control Module: Reset Procedure NOTE: All OBD II scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears oxygen sensor test data. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation STAR (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTC's. New Generation STAR and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. To reset Keep Alive Random Access Memory, disconnect the battery ground cable for a minimum of 5 minutes. Resetting Keep Alive RAM will clear learned values the PCM has stored for adaptive systems such as idle and fuel trim. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 261 Engine Control Module: Removal and Replacement REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly. 3. Remove the wiring harness retaining bolt and wiring connector cover. 4. Disconnect the wiring harness. 5. Remove the retaining nuts and the Powertrain Control Module (PCM). INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 265 Engine Compartment Fuse Box (Part 2 Of 2) The PCM Power Relay is located at LH front of engine compartment, in engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 271 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Fuel Pump Relay: Locations Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Page 275 Engine Compartment Fuse Box (Part 1 Of 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Page 276 Engine Compartment Fuse Box (Part 2 Of 2) The Fuel Pump Relay is located in the LH front of engine compartment, in engine compartment fuse box Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 279 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 280 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 281 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 282 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 283 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 284 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 285 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 289 Engine Compartment Fuse Box (Part 2 Of 2) The PCM Power Relay is located at LH front of engine compartment, in engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-18 > Oct > 06 > Restraints - Air Bag Lamp ON/DTC's B1876/B1880/B1920 Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/DTC's B1876/B1880/B1920 TSB 06-21-18 10/30/06 DTC B1876, B1880, B1915 AND/OR B1920 IN THE ECS MODULE DUE TO HIGH CURRENT AFTERMARKET DEVICES FORD: 1997-2006 E-Series This article supersedes TSB 05-2-8 to update the vehicle model years. ISSUE Some vehicles with high-current aftermarket devices (such as motors for wheel chair lifts) operating at 75 amps or higher may cause electrical transients (voltage spikes), leading to damage of the airbag electronic crash sensor (ECS) module. If this occurs, the airbag lamp will turn on indicating a fault in the airbag system and diagnostic trouble codes (DTC) B1876, B1880, B1915 and/or B1920 will be present. ACTION Follow normal diagnostics per Workshop Manual, Section 501-20B. If pinpoint tests lead to replacement of the ECS module, and the vehicle does contain high-current aftermarket equipment, installation of an ECS module circuit protection improvement kit is recommended. This will prevent recurring damage to the new ECS module. SERVICE PROCEDURE Refer to the kit installation instructions. Cost of the protection kit and installation expenses are the responsibility of the modifier or customer. NOTE READ AND FOLLOW ALL WARNINGS LOCATED IN WORKSHOP MANUAL, SECTION 501-20B BEFORE PERFORMING ANY PROCEDURE OR TESTS ON THE RESTRAINTS SYSTEM. Parts Block WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-18 > Oct > 06 > Restraints Air Bag Lamp ON/DTC's B1876/B1880/B1920 Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/DTC's B1876/B1880/B1920 TSB 06-21-18 10/30/06 DTC B1876, B1880, B1915 AND/OR B1920 IN THE ECS MODULE DUE TO HIGH CURRENT AFTERMARKET DEVICES FORD: 1997-2006 E-Series This article supersedes TSB 05-2-8 to update the vehicle model years. ISSUE Some vehicles with high-current aftermarket devices (such as motors for wheel chair lifts) operating at 75 amps or higher may cause electrical transients (voltage spikes), leading to damage of the airbag electronic crash sensor (ECS) module. If this occurs, the airbag lamp will turn on indicating a fault in the airbag system and diagnostic trouble codes (DTC) B1876, B1880, B1915 and/or B1920 will be present. ACTION Follow normal diagnostics per Workshop Manual, Section 501-20B. If pinpoint tests lead to replacement of the ECS module, and the vehicle does contain high-current aftermarket equipment, installation of an ECS module circuit protection improvement kit is recommended. This will prevent recurring damage to the new ECS module. SERVICE PROCEDURE Refer to the kit installation instructions. Cost of the protection kit and installation expenses are the responsibility of the modifier or customer. NOTE READ AND FOLLOW ALL WARNINGS LOCATED IN WORKSHOP MANUAL, SECTION 501-20B BEFORE PERFORMING ANY PROCEDURE OR TESTS ON THE RESTRAINTS SYSTEM. Parts Block WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 309 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 310 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 316 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 317 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 318 Air Bag Control Module: Specifications Electronic Crash Sensor Module Bolts................................................................................................. .............................................11-13 N.m (8-10 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 319 Air Bag Control Module: Locations Instrument Panel Views The Air Bag Electronic Crash Sensor is located below the RH side (Passenger Side) of the instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 320 Air Bag Electronic Crash Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 321 Air Bag Control Module: Description and Operation The air bag Electronic Crash Sensor (ECS) module performs the following functions: - deploys the air bags and seat belt pretensioners in the event of a deployable crash. - monitors the air bag Supplemental Restraint System (SRS) for faults. - illuminates the air bag indicator if a fault is detected. - flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. - communicates through the Data Link Connector (DLC) the current and historical Diagnostic Trouble Codes (DTCs). - activates a chime or buzzer if the air bag indicator is not available. The ECS, together with the primary crash sensor, determines when to deploy the air bags and belt and buckle assembly pretensioners. The ECS monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the ECS will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off then turned on), the air bag indicator will flash the two-digit lamp fault code (LFC). The air bag indicator will flash the LFC twice, then it will remain illuminated for the rest of the key cycle. The ECS will also communicate the current and historical DTCs through the data link connector (DLC), using the New Generation Star (NGS) Tester. If the air bag indicator does not function, and the system detects a fault condition, the ECS will activate an audible chime or buzzer. The chime is a series of five sets of five tone bursts. The buzzer is a five-seconds-on, five-seconds-off buzzing noise. If the chime or buzzer is heard, the SRS or the air bag indicator requires service. Lamp fault codes are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. The ECS includes an internal backup power supply. This feature provides sufficient backup power to deploy the air bag in the event the battery or battery cables are damaged in a collision before the safing and primary crash sensors close. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. There are three types of 1998 E-Series ECS modules: a two-ignitor system for a school bus, a three-ignitor system for a cargo van and a four-ignitor system for a passenger van. These ECS modules have unique part numbers and are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 322 Air Bag Control Module: Service and Repair Removal WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: The safing sensor is internal to the air bag Electronic Crash Sensor (ECS) module and is not replaced separately. 1. Disconnect the battery ground cable(s). 2. Remove the RH cowl side trim panel. 3. Disconnect the air bag electronic crash sensor (ECS) module electrical connector. 1. Disconnect the ECS electrical connector locking clip. 2. Disconnect the ECS electrical connector. 4. Remove the air bag electronic crash sensor (ECS) module. 1. Remove the ECS module retaining bolts. 2. Remove the ECS module. Installation Follow the Removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications Starter Relay: Specifications Starter Motor Solenoid Relay Switch Mounting Bolts ........................................................................................................................ 7-9 N.m (61-79 Lb/In) Starter Motor Relay Mounting Screws ................................................................................................................................................ 7-9 N.m (62-80 Lb/In) Starter Motor Relay B+ and Enable terminal Nuts .............................................................................................................................. 7-9 N.m (62-80 Lb/In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 327 Starter Relay: Locations The Starter Motor Relay is located at the RH front corner of the engine compartment, near battery. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 328 Starter Relay: Description and Operation The starter motor solenoid relay switch: - controls current to the starter solenoid. - is engaged by the ignition switch. - connects the battery to the starter motor. The Transimission Range (TR) sensor on automatic transmission-equipped vehicles prevents starter motor engagement unless the transmission is in the NEUTRAL or PARK position Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 329 Starter Relay: Service and Repair REMOVAL WARNING: WHEN REPAIRING THE STARTER MOTOR OR PERFORMING OTHER UNDERHOOD WORK IN THE VICINITY OF THE STARTER MOTOR, BE AWARE THAT THE HEAVY GAUGE BATTERY INPUT LEAD AT THE STARTER SOLENOID IS ELECTRICALLY HOT AT ALL TIMES. THE PROTECTIVE CAP OR BOOT PROVIDED OVER THIS TERMINAL MUST BE REPLACED AFTER MAINTENANCE IS COMPLETE. MAKE SURE TO DISCONNECT THE BATTERY GROUND CABLE BEFORE WORKING ON THE STARTER MOTOR. 1. Disconnect the battery ground cable. 2. Remove the relay cover. 3. Disconnect the starter motor solenoid relay switch wires and cables. 1. Remove the insulator. 2. Disconnect the starter motor relay trigger terminal connector. 3. Remove the starter motor solenoid relay switch terminal nuts. 4. Remove the engine control sensor wire and the generator wire. 5. Remove the battery cables. 4. Remove the starter motor solenoid relay switch. 1. Remove the bolts. 2. Remove the starter motor solenoid relay switch. INSTALLATION WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM, BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE THE PROTECTIVE CAPS ARE IN PLACE WHEN THE MAINTENANCE IS COMPLETE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 330 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations Windshield Washer Control Module: Locations Wiper Control Module And Bracket Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations > Page 335 Windshield Washer Control Module: Service and Repair REMOVAL 1. Remove the engine cover. 2. Remove the wiper module. 1 Disconnect the electrical connector. 2 Push the detent tabs on the wiper control module through the holes in the mounting bracket and slide the module off the bracket. 3 Remove the wiper control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Instrument Panel Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 339 Wiper Control Module And Bracket The Wiper Control Module is located behind center side of the instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 340 Wiper Control Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 341 Wiper Control Module: Service and Repair REMOVAL 1. Remove the engine cover. 2. Remove the wiper module. 1 Disconnect the electrical connector. 2 Push the detent tabs on the wiper control module through the holes in the mounting bracket and slide the module off the bracket. 3 Remove the wiper control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch Master Window/Door Lock Control Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 348 Rear Power Door Lock Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 349 RH Power Door Lock/Window Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Power Mirror Switch (Without Door Trim) (C508) Power Mirror Switch (Without Door Trim) (C505) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 353 Power Mirror Switch: Service and Repair REMOVAL 1. Pry the plate assembly upward. 2. Disconnect the electrical connector and remove the switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest: > 98-20-19 > Oct > 98 > Power Seat Switch Button Comes Off Power Seat Switch: Customer Interest Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: All Technical Service Bulletins Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 372 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 373 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 379 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Switch: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 380 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 381 Driver's Seat Regulator Control Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 382 Power Seat Switch: Service Precautions WARNING THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG-EQUIPPED VEHICLE AND WHEN HANDLING A BELT AND BUCKLE ASSEMBLY PRETENSIONER. - THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. NEVER PROBE THE CONNECTORS ON THE BELT AND BUCKLE ASSEMBLY PRE TENSIONER. DOING SO CAN RESULT IN BELT AND BUCKLE ASSEMBLY PRETENSIONER OR AIR BAG DEPLOYMENT AND CAN RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF SO EQUIPPED). NOTE: Be sure to disconnect auxiliary batteries and power supplies (if so equipped). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 383 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable(s). WARNING THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG-EQUIPPED VEHICLE AND WHEN HANDLING A BELT AND BUCKLE ASSEMBLY PRETENSIONER. - THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. NEVER PROBE THE CONNECTORS ON THE BELT AND BUCKLE ASSEMBLY PRE TENSIONER. DOING SO CAN RESULT IN BELT AND BUCKLE ASSEMBLY PRETENSIONER OR AIR BAG DEPLOYMENT AND CAN RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF SO EQUIPPED). NOTE: Be sure to disconnect auxiliary batteries and power supplies (if so equipped). 2. Remove the front seat from the vehicle. 1 Remove the plastic bolt covers. 2 Remove the nuts and bolts. 3 Disconnect the belt and buckle assembly pretensioner connector. 4 Remove the front seat NOTE: The front seat does not need to be removed in order to remove the seat control switch, but it may be easier to access the wiring connector and switch fasteners if the seat is removed. 3. Disconnect the power seat control switch connector. 4. Remove the appropriate seat back latch cover to access the switch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 384 5. Remove the power seat control switch. 1 Pull the front seat back latch lower cover away from the seat. 2 Pull the power seat control switch connector through the seat cushion. 3 Remove the screws. 4 Remove the power seat control switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Fluid Level Sensor/Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 390 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 391 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 392 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 393 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 394 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 395 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 396 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 397 Brake Fluid Level Sensor/Switch: Description and Operation The Brake Fluid Level Sensor is incorporated into the Dual Brake Warning Switch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Rear Anti-Lock Brakes Wheel Speed Sensor: Specifications Rear Anti-Lock Brake Sensor Pole Piece To Rear Anti-Lock Brake Sensor Indicator Clearance 0.005-0.045 in Rear Anti-Lock Brake Sensor Bolt 25-29 ft.lb Rear Anti-Lock Brake Sensor Nuts 15-21 ft.lb Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Rear Anti-Lock Brakes > Page 402 Wheel Speed Sensor: Specifications Front Anti-Lock Brake Sensor Bolt 62-80 in.lb Front Anti-Lock Brake Sensor Wire Retaining Bolt 7-9 ft.lb Rear Anti-Lock Sensor Bolt 25-29 ft.lb Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Rear Axle Speed Sensor Wheel Speed Sensor: Locations Rear Axle Speed Sensor Full Body Views The Rear Axle Speed Sensor is located below the rear of vehicle, mounted on differential. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Rear Axle Speed Sensor > Page 405 Wheel Speed Sensor: Locations Wheel Speed Sensor Left Front Full Body Views The Left Front Wheel Sensor is located behind LH front wheel. Right Front Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Rear Axle Speed Sensor > Page 406 Full Body Views The Right Front Wheel Sensor is located near right front wheel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring Wheel Speed Sensor: Service and Repair Toothed Ring Front REMOVAL 1. Remove the front disc brake rotor. 2. Use 2-3 Jaw Puller to remove the front anti-lock brake sensor indicator. CAUTION: Discard the front anti-lock brake sensor indicator. INSTALLATION 1. Use an appropriate size cylinder and press to install the front anti-lock brake sensor indicator. CAUTION: The front anti-lock brake sensor indicator must be pressed on straight. 2. Install the front disc brake rotor. Rear For removal and installation of the rear brake anti-lock sensor indicator, refer to Differential. NOTE: The rear anti-lock brake sensor indicator is attached to the ring gear. It is necessary to remove the ring gear in order to remove the rear anti-lock brake sensor indicator. Rear Antilock Brake System (RABS) For removal and installation of the rear brake anti-lock sensor indicator, refer to Differential. NOTE: The rear anti-lock brake sensor indicator is attached to the ring gear. It is necessary to remove the ring gear in order to remove the rear anti-lock brake sensor indicator. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 409 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Rear Antilock Brake System REMOVAL 1. Raise and support the vehicle. 2. Remove the rear anti-lock brake sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. CAUTION: Do not get dirt in the rear axle housing. INSTALLATION 1. Clean and inspect the rear anti-lock brake sensor. 1 Clean the rear axle housing mounting surface. 2 Inspect and clean the magnetized sensor pole piece. 3 Inspect the sensor and O-ring for damage. Replace if necessary. 4 Lightly lubricate the O-ring with motor oil. CAUTION: Do not get dirt in the rear axle housing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 410 2. Measure the clearance between the rear anti-lock brake sensor pole piece and the rear anti-lock brake sensor indicator. 3. Install the rear anti-lock brake sensor. 1 Position the sensor and install the bolt. NOTE: Do not apply force to the plastic rear anti-lock brake sensor connector. The rear anti-lock brake sensor flange should slide to the mounting surface. 2 Connect the electrical connector. Front REMOVAL 1. Remove the front disc brake rotor. 2. Detach the front anti-lock brake sensor wire from the front brake hose. 1 Disconnect the front anti-lock brake sensor electrical connector. 2 Detach the front anti-lock brake sensor wire from the front brake hose. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 411 3. Remove the bolt. 4. Remove the front anti-lock brake sensor. 1 Remove the front anti-lock brake sensor bolts. 2 Remove the front anti-lock brake sensor. INSTALLATION 1. To install, reverse the removal procedure. Rear REMOVAL 1. Raise and support vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 412 2. Remove the rear anti-lock brake sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. INSTALLATION CAUTION: Use care not to get dirt in the rear axle housing. 1. Clean and inspect the rear anti-lock brake sensor. 1 Clean the axle mounting surface. 2 Inspect and clean the rear anti-lock brake sensor. 3 Inspect the rear anti-lock brake sensor O-ring for damage. Replace if necessary. 4 Lightly lubricate the rear anti-lock brake sensor O-ring with Synthetic SAE 75W 140 Rear Axle Lubricant F1TZ-19580-A or equivalent meeting Ford specification WSL-M2C192-A. 2. Install the rear anti-lock brake sensor. 1 Position the rear anti-lock brake sensor and install the bolt. 2 Connect the electrical connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 413 CAUTION: Do not apply force to the plastic rear anti-lock brake sensor connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Page 414 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 420 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 421 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Partially drain the cooling system. 3. Remove the Engine Coolant Temperature sensor (ECT sensor). 1. Disconnect the electrical connector. 2. Remove the ECT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Engine Temperature Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 425 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 426 Engine Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Generator (GEN). 3. Remove cylinder head temperature sensor. 1. Disconnect the electrical connector. 2. Remove the CHT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications TORQUE SPECIFICATIONS Water Temperature Indicator Sender Unit ................................................................................................................................. 16-24 Nm (12-18 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 430 Temperature Sensor (Gauge): Locations Engine Views The Instrumentation Engine Coolant Temperature Sensor is located on the upper left front of engine. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 431 Temperature Sensor (Gauge): Service and Repair REMOVAL 1. Remove the air cleaner assembly. 2. Partially drain the cooling system. 3. Disconnect the electrical connector. Remove the engine coolant temperature sensor from the intake manifold. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 445 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 446 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 447 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 448 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 449 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 450 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 451 Attachment III - Technical Information Table of Contents Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 452 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 453 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 454 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 455 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 456 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 457 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 458 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 459 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 460 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 461 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 462 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 463 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 464 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 465 ERROR: stackunderflow OFFENDING COMMAND: begin STACK: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness Technical Service Bulletin # 08S01S1 Date: 080410 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 470 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS was activated February 6, 2008. FSA VIN LIST ACTIVATED? Yes, VIN lists are available through NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 471 ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. [New!] CLAIMS PREPARATION AND SUBMISSION ^ It is no longer necessary for dealers to manually enter labor operation times for vehicles built prior to the 1997 model year. ^ Enter claims using Direct Warranty Entry (DWE). ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. ^ Claiming Information for Electrical Grease II (Submit on same repair line as repair.) - Program Code: 08S01 - Misc. Expense: OTHER - Misc. Expense: $6.07 NOTE: Electrical Grease II can only be claimed when Labor Operation 08S01EE or 08S01GG is claimed. (Do not claim as "Normal Shop Supplies".) ^ Refer to ACESII manual for claims preparation and submission information. Enter claims using Direct Warranty Entry (DWE). Attachment II - Labor and Parts Information [New!] LABOR ALLOWANCES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 472 [New!] Vehicle Parts Application & Labor Operation Chart Description of Labor Operations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 473 [New!] PARTS REQUIREMENTS / ORDERING INFORMATION [New!] SEED STOCK PLAN Refer to Safety Recall 05S28 Supplement # 15 for seed stock plans. Dealers will be notified via DOES II when open ordering begins or if seed stock quantites change. NOTE: If any of the necessary parts are needed to service specific vehicles, contact the Special Service Support Center. Please be prepared to provide your P&A; Code, vehicle VIN and vehicle owner name. Questions regarding parts should be directed to the Special Service Support Center or E-mailed to. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment III - Technical Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 474 Table of Contents OVERVIEW This program involves removing the 4W1Z-14A411-BC Fused Jumper Harness (FJH) that was previously installed during service on the affected vehicles and installing a Universal Fused Jumper Harness (UFJH), or a new Speed Control Deactivation Switch (SCDS). NOTE: Do not perform an Interim Repair (SCDS Disconnect) on any of the affected vehicles in this program. Call the Special Service Support Center if you do not have the necessary parts to complete the final repairs. SPEED CONTROL DEACTIVATION SWITCH (SCDS) LOCATION In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder, but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-1 50/250/350 it may be necessary to lift the vehicle to disconnect the SCDS. Remove the electrical connector from the speed control deactivation switch and check the fused jumper harness connector end for the presence of brake fluid. Cut the tie straps from the fused jumper harness 4W1 Z-1 4A41 1-BC and remove the fused jumper harness. ^ If there is no evidence of brake fluid on the connector, install a Universal Fused Jumper Harness. ^ If there is the presence of brake fluid on the connector, replace the Speed Control Deactivation Switch. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 475 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 1. PARTS APPLICATION CHART UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the universal fused jumper harness (Part Number 8W7Z-14A411-C) to the SCDS and the vehicle harness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 476 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 2. LEAKING SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 3. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 477 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 6. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 4. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to new step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 7. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. 8. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 9. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 5. 10. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 478 11. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 6. 12. Reconnect the servo connector. 13. Release the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 479 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 480 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 481 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 482 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 483 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 488 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 498 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 499 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 500 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 501 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 502 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 503 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 504 Attachment III - Technical Information Table of Contents Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 505 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 506 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 507 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 508 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 509 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 510 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 511 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 512 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 513 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 514 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 515 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 516 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 517 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 518 ERROR: stackunderflow OFFENDING COMMAND: begin STACK: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness Technical Service Bulletin # 08S01S1 Date: 080410 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 523 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS was activated February 6, 2008. FSA VIN LIST ACTIVATED? Yes, VIN lists are available through NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 524 ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. [New!] CLAIMS PREPARATION AND SUBMISSION ^ It is no longer necessary for dealers to manually enter labor operation times for vehicles built prior to the 1997 model year. ^ Enter claims using Direct Warranty Entry (DWE). ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. ^ Claiming Information for Electrical Grease II (Submit on same repair line as repair.) - Program Code: 08S01 - Misc. Expense: OTHER - Misc. Expense: $6.07 NOTE: Electrical Grease II can only be claimed when Labor Operation 08S01EE or 08S01GG is claimed. (Do not claim as "Normal Shop Supplies".) ^ Refer to ACESII manual for claims preparation and submission information. Enter claims using Direct Warranty Entry (DWE). Attachment II - Labor and Parts Information [New!] LABOR ALLOWANCES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 525 [New!] Vehicle Parts Application & Labor Operation Chart Description of Labor Operations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 526 [New!] PARTS REQUIREMENTS / ORDERING INFORMATION [New!] SEED STOCK PLAN Refer to Safety Recall 05S28 Supplement # 15 for seed stock plans. Dealers will be notified via DOES II when open ordering begins or if seed stock quantites change. NOTE: If any of the necessary parts are needed to service specific vehicles, contact the Special Service Support Center. Please be prepared to provide your P&A; Code, vehicle VIN and vehicle owner name. Questions regarding parts should be directed to the Special Service Support Center or E-mailed to. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment III - Technical Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 527 Table of Contents OVERVIEW This program involves removing the 4W1Z-14A411-BC Fused Jumper Harness (FJH) that was previously installed during service on the affected vehicles and installing a Universal Fused Jumper Harness (UFJH), or a new Speed Control Deactivation Switch (SCDS). NOTE: Do not perform an Interim Repair (SCDS Disconnect) on any of the affected vehicles in this program. Call the Special Service Support Center if you do not have the necessary parts to complete the final repairs. SPEED CONTROL DEACTIVATION SWITCH (SCDS) LOCATION In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder, but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-1 50/250/350 it may be necessary to lift the vehicle to disconnect the SCDS. Remove the electrical connector from the speed control deactivation switch and check the fused jumper harness connector end for the presence of brake fluid. Cut the tie straps from the fused jumper harness 4W1 Z-1 4A41 1-BC and remove the fused jumper harness. ^ If there is no evidence of brake fluid on the connector, install a Universal Fused Jumper Harness. ^ If there is the presence of brake fluid on the connector, replace the Speed Control Deactivation Switch. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 528 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 1. PARTS APPLICATION CHART UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the universal fused jumper harness (Part Number 8W7Z-14A411-C) to the SCDS and the vehicle harness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 529 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 2. LEAKING SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 3. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 530 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 6. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 4. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to new step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 7. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. 8. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 9. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 5. 10. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 531 11. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 6. 12. Reconnect the servo connector. 13. Release the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 532 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 533 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 534 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 535 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 536 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 541 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 542 Brake Switch (Cruise Control): Specifications Deactivator Switch ............................................................................................................................... ........................................... 15-20 N.m (11-14 Lb-Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 543 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the deactivator switch electrical connector, and remove the deactivator switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. - After the deactivator switch is installed, it is necessary to bleed the brake system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 552 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 553 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 554 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 555 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 556 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 557 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 558 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 559 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 560 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 561 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 562 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 563 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 564 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 565 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 566 Owner Letter Owner Letter not available at this time. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 572 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 573 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 574 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 575 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 576 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 577 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 578 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 579 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 580 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 581 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 582 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 583 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 584 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 585 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 586 Owner Letter Owner Letter not available at this time. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 605 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 606 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 612 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 613 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 614 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the driver side air bag module. 2. Remove the speed control actuator switches. 1. Disconnect the speed control actuator switch electrical connector. 2. Remove the two bolts. 3. Remove the speed control actuator switches. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Front Blower Switch Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Front Blower Switch Schematic > Page 620 C 207 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Front Blower Switch Schematic > Page 621 Auxiliary Heater Blower Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Front Blower Switch Schematic > Page 622 Auxiliary Air Conditioner-Heater Blower Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary Blower Motor Switch: Testing and Inspection Auxiliary Auxiliary A/C-Heater Blower Switch - Component Testing Procedure Auxiliary A/C-Heater Blower Switch - Terminal Locations Auxiliary A/C-Heater Blower Switch - Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary > Page 625 Blower Motor Switch: Testing and Inspection Front Blower Switch Front Blower Switch - Component Testing Procedure Front Blower Switch - Terminal Locations Front Blower Switch - Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary > Page 626 Blower Motor Switch: Testing and Inspection Rear Auxiliary Rear Auxiliary Blower Switch - Component Testing Procedure Rear Auxiliary Blower Switch - terminal Locations Rear Auxiliary Blower Switch - Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications A/C Cycling Switch .............................................................................................................................. ......................................... 1.4-3.8 N.m (13-33 Lb/In) A/C Pressure Cut-Off Switch .......................................................................................................................................................... 7-13 N.m (61-121 Lb/In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 631 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Cycling Switch Close Maximum ................................................................................................................................... ............................................... 324 kPa (47 psi) Open Minimum ......................................................... .......................................................................................................................... 152 kPa (22 psi) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch A/C Pressure Cut-Off Switch The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1724 kPa (250 psi), the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 634 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier. - 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 inside the suction accumulator/drier to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). - The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). - When the A/C cycling switch contacts close, the A/C clutch field coil is energized. - When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the A/C cycling switch connector. 2. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. Follow the removal procedure in reverse order. Lubricate the O-ring seal with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 637 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the A/C pressure cut-off switch electrical connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seal with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1. Disconnect the electrical connector. 2. Rotate switch counterclockwise. 3. Remove the interior lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation The key-in-ignition warning chime/buzzer will sound continuously when the ignition key is in the ignition switch lock cylinder with the key OFF and the driver door open. The chime/buzzer will continue to sound until the key is removed from the ignition switch lock cylinder or the driver door is closed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 649 Backup Lamp Switch: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 650 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation Brake Light Switch: Description and Operation Exterior Lighting System Components The stoplight switch controls the brake lamps, and rear hi-mount lamp. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 654 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 3. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the brake master cylinder push rod spacer. 3 Remove the BPP switch from the brake master cylinder push rod. 4 Remove the brake master cylinder push rod bushing. 5 Remove the brake master cylinder push rod spacer. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1. Disconnect the electrical connector. 2. Rotate switch counterclockwise. 3. Remove the interior lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 661 Hazard Warning Switch: Diagrams Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 662 Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 663 Hazard Warning Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. - Ignition. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis Hazard Warning Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 666 Hazard Warning Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 667 Hazard Warning Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 668 Hazard Warning Switch: Pinpoint Tests Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 669 C1 Part 2 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 670 Part 3 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 671 Hazard Warning Switch: Component Tests and General Diagnostics Terminals Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 672 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 673 1. Measure the resistance between the multi-function switch terminals. - If the resistances are as specified, the multi-function switch is OK. Return the multi-function switch to the vehicle. Test the system for normal operation. - If the resistances are not as specified, replace the multi-function switch. Test the system for normal operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 674 Hazard Warning Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 4. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 675 5. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 679 Headlamp Dimmer Switch: Diagrams Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 680 Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 681 Headlamp Dimmer Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. - Ignition. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Headlamp Dimmer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 684 Headlamp Dimmer Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 685 Headlamp Dimmer Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 686 Headlamp Dimmer Switch: Pinpoint Tests Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 687 C1 Part 2 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 688 Part 3 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 689 Headlamp Dimmer Switch: Component Tests and General Diagnostics Terminals Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 690 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 691 1. Measure the resistance between the multi-function switch terminals. - If the resistances are as specified, the multi-function switch is OK. Return the multi-function switch to the vehicle. Test the system for normal operation. - If the resistances are not as specified, replace the multi-function switch. Test the system for normal operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 692 Headlamp Dimmer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 4. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 693 5. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Main Light Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 697 Headlamp Switch: Description and Operation Exterior Lighting System Components The headlamp switch is a three-position switch that controls the headlamps, exterior lamps, and panel lamps. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 698 Headlamp Switch: Testing and Inspection Main Light Switch-Component Testing Procedure Main Light Switch - Terminal Locations Main Light Switch - Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 699 Headlamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 3. Remove the headlamp switch bolts. 4. Disconnect the electrical connector and remove the headlamp switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 703 Turn Signal Switch: Diagrams Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 704 Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 705 Turn Signal Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. - Ignition. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis Turn Signal Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 708 Turn Signal Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 709 Turn Signal Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 710 Turn Signal Switch: Component Tests and General Diagnostics Terminals Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 711 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 712 1. Measure the resistance between the multi-function switch terminals. - If the resistances are as specified, the multi-function switch is OK. Return the multi-function switch to the vehicle. Test the system for normal operation. - If the resistances are not as specified, replace the multi-function switch. Test the system for normal operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 713 Turn Signal Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 4. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 714 5. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 725 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 726 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 732 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 733 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness Wiring Harness: All Technical Service Bulletins Recall 08V051000: Incorrect Speed Control Jumper Harness MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1994-2003 Ford/E-250 1994-2003 Ford/E-350 1994-2003 Ford/E150 1992-1993 Ford/E250 1992-1993 Ford/E350 1992-1993 Ford/Econoline 1992-2003 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-1997 Ford/Taurus SHO 1993-1995 Lincoln/Town Car 1992-1995 Mercury/Grand Marquis 1992-1998 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: February 01, 2008 NHTSA CAMPAIGN ID NUMBER: 08V051000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control: Cruise Control POTENTIAL NUMBER OF UNITS AFFECTED: 225000 SUMMARY: Ford is recalling 225,000 M?Y 1992-2003 Econoline, M/Y 1993-1995 Taurus SHO, M/Y 1992-1998 Crown Victoria, M/Y 1993 Bronco, F-Series, M/Y 1995-1997 F-Series Super Duty Stripped Chassis, M/Y 1992-1998 Mercury Grand Marquis, and M/Y 1992-1995 Lincoln Town Car vehicles. The affected vehicles were previously repaired using a wiring harness that is not compatible with the vehicle circuit polarity. CONSEQUENCE: As a result, the fuse is located in the output circuit rather than in the intended input power feed circuit, and may not offer the intended protection in the event of an electrical short to ground. REMEDY: Dealers will install a new wiring harness, or replace the mating electrical component. The recall is expected to begin during February 2008. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 08S01. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness > Page 739 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness > Page 745 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 746 Air Flow Meter/Sensor: Locations Engine Compartment Views The Mass Air Flow Sensor is located at the center of the engine compartment. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 747 Air Flow Meter/Sensor: Service and Repair 1. Disconnect the battery ground cable. NOTE: The sensing element located inside the Mass Air Flow sensor (MAF sensor) can be damaged by touching. 2. Remove the air cleaner assembly. 3. Separate the two halves of the air cleaner housing. 4. Disconnect the wiring connector from housing. 5. Remove the mounting plate and mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 756 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 757 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 758 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 759 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 760 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 761 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 762 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 763 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 764 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 765 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 766 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 767 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 768 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 774 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 775 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 776 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 777 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 778 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 779 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 780 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 781 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 782 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 783 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 784 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 785 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 786 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 787 Camshaft Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 788 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 789 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. The 4.6L Engine Is Shown; 5.4L And 6.8L Are Similar 2. Remove the Camshaft Position sensor (CMP sensor). 1. Disconnect the electrical connector. 2. Remove the bolt. 3. Remove the CMP sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 793 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 794 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Partially drain the cooling system. 3. Remove the Engine Coolant Temperature sensor (ECT sensor). 1. Disconnect the electrical connector. 2. Remove the ECT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications TORQUE SPECIFICATIONS Crankshaft Position Sensor Bolt ............................................................................................................................................. 8-12 Nm (71-106 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 798 Crankshaft Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 799 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 800 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Release tension on the accessory drive belt. 4. Position the A/C compressor aside. NOTE: Do not remove the lines from the A/C compressor. 5. Disconnect the wiring at the sensor. 6. Remove the CKP sensor bolt and the Crankshaft Position sensor (CKP sensor). NOTE: The crankshaft pulley is shown removed for clarity. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Engine Temperature Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 804 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 805 Engine Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Generator (GEN). 3. Remove cylinder head temperature sensor. 1. Disconnect the electrical connector. 2. Remove the CHT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Fuel Tank Pressure Sensor: Locations Full Body Views The Fuel Tank Pressure Sensor is located under LH center of vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 809 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor. 1. Disconnect the electrical connector. 2. Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. Follow the removal procedure in reverse order. 2. Perform the evaporative emission system leak test. 3. Perform the evaporative emission running loss monitor repair verification drive cycle test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Engine Compartment Views The Intake Air Temperature Sensor is located at the Center of the engine compartment, part of clean air tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 813 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly. 3. Disconnect the Intake Air Temperature sensor (IAT sensor) electrical connector, and remove the sensor from the air intake tube. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 817 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 818 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Remove the Knock Sensor (KS). 1. Disconnect the electrical connector. 2. Remove the knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics Oxygen Sensor: Technical Service Bulletins Engine Controls - Bi-Fuel O2 Sensor Diagnostics Article No. 03-6-6 03/31/03 DRIVEABILITY - BI-FUEL - OXYGEN SENSOR DIAGNOSTICS - HIGH OXYGEN SENSOR VOLTAGE READING FORD: 1998-2000 CONTOUR 1998-1999 E SERIES 1998-2003 F-150 1999 F-250 ISSUE Some Bi-Fuel vehicles may exhibit DTC's for high Oxygen Sensor voltage (P0132 and P0152). Current diagnostics may result in premature replacement of the Compuvalve. ACTION If an Oxygen Sensor code is set, the current diagnostics direct the Compuvalve to be replaced it no faults are detected when Pinpoint Test H is conducted. The modified repair action outlined below gives additional test procedures if nothing is detected from Pinpoint Test H. SERVICE PROCEDURE 1. Prior to clearing any codes, to aid in diagnostics of intermittent failures, access and record the freeze frame data using the NGS Tester. 2. At step H4 of the pinpoint test, it Oxygen Sensor PIDS (H02S11 and H02521) are within specification (see table in Section H of PC/ED Manual), clear codes and road test the vehicle in alternative fuel using the freeze frame data (from above) to duplicate conditions that triggered the code. During the road test, monitor Oxygen Sensor PIDs for both banks in both the PCM and the AFCM. NOTE A SECOND TECHNICIAN SHOULD MONITOR THE PIDS WHILE THE OTHER DRIVES. IF THE CODE/CONCERN CANNOT BE DUPLICATED, REFER TO PINPOINT TEST Z OF THE BASE VEHICLE PC/ED. 3. If the concern is duplicated, and if voltage is outside of specifications in both the AFCM and the PCM, the fault is in the Heated Exhaust Gas Oxygen (HEGO) sensor circuit. Refer to base vehicle diagnostics. 4. If the voltage is outside of specifications in the AFCM only, replace the Compuvalve. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 490000, 698298 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 823 Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 824 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 825 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 826 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 827 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 828 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 829 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 830 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 831 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 832 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 833 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 834 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 835 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 836 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 837 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 838 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 841 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 844 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 845 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 846 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 847 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 848 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 849 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 850 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 851 Oxygen Sensor: Connector Views Ford does not provide connector views for this vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 852 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 853 Oxygen Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the engine cover. 3. Disconnect the wiring. 4. Raise the vehicle. 5. Remove the sensors. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Locations Pressure Feedback Exhaust Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Locations > Page 857 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 861 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 862 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly and throttle body splash shield. 3. Disconnect the wiring at the Throttle Position sensor (TP sensor). 4. Remove the retaining screws and sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor .............................................................................................................................................. 8-10 Nm (75-85 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 866 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 867 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 868 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 869 Transmission Position Switch/Sensor: Service and Repair Special Tools REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1. Remove the bolts. 2. Remove the sensor. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 870 1. Install the digital transmission range (TR) sensor. 1. Install the sensor. 2. Loosely install the bolts. 2. Install the Digital Transmission Range (TR) Sensor Alignment Tool. NOTE: Make sure that the manual control lever is in the neutral position. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 871 5. Reconnect the connector. 6. Reconnect the battery ground cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor-to-Case ....................................................................................................................................................... 49-73 Nm (36-54 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 875 Vehicle Speed Sensor: Locations Transmission View The Vehicle Speed Sensor is located under vehicle, on the left side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 878 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 879 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 880 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 881 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 882 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 883 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 884 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 885 Vehicle Speed Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the Vehicle Speed Sensor (VSS). 1. Disconnect the VSS electrical connector. 2. Remove the bolt. 3. Remove the VSS. 3. Remove the vehicle speed sensor driven gear. 1. Remove the retaining clip. 2. Remove the driven gear. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 886 1. Install the vehicle speed sensor driven gear. 1. Install the driven gear. 2. Install the retaining clip. 2. Install the Vehicle Speed Sensor (VSS). 1. Install the VSS. 2. Install the bolt. 3. Connect the electrical connector. 3. Lower the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 891 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 901 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 902 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 908 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 909 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 915 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 916 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 922 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 923 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Technical Service Bulletins > Page 924 Air Flow Meter/Sensor: Locations Engine Compartment Views The Mass Air Flow Sensor is located at the center of the engine compartment. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Technical Service Bulletins > Page 925 Air Flow Meter/Sensor: Service and Repair 1. Disconnect the battery ground cable. NOTE: The sensing element located inside the Mass Air Flow sensor (MAF sensor) can be damaged by touching. 2. Remove the air cleaner assembly. 3. Separate the two halves of the air cleaner housing. 4. Disconnect the wiring connector from housing. 5. Remove the mounting plate and mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Full Body Views The Fuel Tank Temperature Sensor is located under LH center of vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Inertia Fuel Shutoff Switch: Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 932 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 933 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. The IFS 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. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Throttle Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 937 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 938 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly and throttle body splash shield. 3. Disconnect the wiring at the Throttle Position sensor (TP sensor). 4. Remove the retaining screws and sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 948 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 949 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 950 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 951 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 952 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 953 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 954 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 955 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 956 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 957 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 958 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 959 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 960 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Component Information > Locations > Page 963 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 03-20-3 > Oct > 03 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 03-20-3 > Oct > 03 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 973 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 03-20-3 > Oct > 03 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 974 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 03-20-3 > Oct > 03 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 975 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 03-20-3 > Oct > 03 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 976 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 03-20-3 > Oct > 03 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 977 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 03-20-3 > Oct > 03 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 978 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 03-20-3 > Oct > 03 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 979 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 03-20-3 > Oct > 03 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 980 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 03-20-3 > Oct > 03 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 981 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 03-20-3 > Oct > 03 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 982 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 03-20-3 > Oct > 03 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 983 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 03-20-3 > Oct > 03 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 984 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 03-20-3 > Oct > 03 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 985 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 993 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 994 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 995 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 996 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 997 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 998 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 999 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1000 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1001 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1002 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1003 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1004 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1005 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 1011 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 1012 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 1013 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 1014 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 1015 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Specifications Idler Pulley: Specifications TORQUE SPECIFICATIONS Idler Pulley Bolt .................................................................................................................................... ..................................... 20-30 Nm (15-22 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Specifications > Page 1018 Idler Pulley: Service and Repair REMOVAL 1. Remove the drive belt. 2. Remove the (A) bolt and the (B) belt idler pulley from the engine timing cover. INSTALLATION 1. Follow the removal procedures in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection For Testing of this and other gauges, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Panel, Testing and Inspection. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications TORQUE SPECIFICATIONS Crankshaft Position Sensor Bolt ............................................................................................................................................. 8-12 Nm (71-106 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1024 Crankshaft Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1025 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1026 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Release tension on the accessory drive belt. 4. Position the A/C compressor aside. NOTE: Do not remove the lines from the A/C compressor. 5. Disconnect the wiring at the sensor. 6. Remove the CKP sensor bolt and the Crankshaft Position sensor (CKP sensor). NOTE: The crankshaft pulley is shown removed for clarity. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1035 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1036 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1037 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1038 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1039 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1040 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1041 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1042 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1043 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1044 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1045 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1046 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1047 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-7-3 > Apr > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-7-3 > Apr > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1057 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-7-3 > Apr > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1058 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-7-3 > Apr > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1059 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-7-3 > Apr > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1060 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-7-3 > Apr > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1061 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-7-3 > Apr > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1062 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-7-3 > Apr > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1063 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-7-3 > Apr > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1064 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-7-3 > Apr > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1065 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-7-3 > Apr > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1066 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-7-3 > Apr > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1067 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-7-3 > Apr > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1068 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-7-3 > Apr > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1069 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > Page 1070 Idle Speed: Specifications With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 780 - 810 RPM Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1076 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1077 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1078 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1079 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1080 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 1081 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Replacement, Functional Ignition Switch Lock Cylinder: Service and Repair Replacement, Functional REMOVAL NOTE: The following procedure applies to vehicles that have functional lock cylinders and keys. If key numbers are known, the proper key can be made. 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Position the lock cylinder to RUN. (2) Using a suitable tool, push upward on the cylinder release tab through the hole in the lower shroud while pulling the cylinder outward. INSTALLATION 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Replacement, Functional > Page 1084 Ignition Switch Lock Cylinder: Service and Repair Replacement, Non-Functional REMOVAL NOTE: The following procedure applies to vehicles in which the ignition lock is inoperative and the lock cylinder cannot be rotated due to a lost or broken key, unknown key number, or a cap that has been damaged or broken to the extent that the lock cylinder cannot be rotated. 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 1/8 inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8 inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Replacement, Functional > Page 1085 6. Remove the bearing and the gear. - Thoroughly clean all drill shavings from the steering column and inspect it for damage. INSTALLATION 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. NOTE: Use a new ignition switch lock cylinder. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1089 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1090 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Remove the Knock Sensor (KS). 1. Disconnect the electrical connector. 2. Remove the knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Primary Crash Sensor Screws............................................................................................................. ...............................................11-13 N.m (8-10 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 1095 Impact Sensor: Locations Engine Compartment Views The Center Air Bag Sensor is located in front center of the engine compartment, behind grille. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 1096 Impact Sensor: Description and Operation WARNING: THE ECS AND PRIMARY CRASH SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION WHERE THE RADIATOR GRILLE, FRAME RAILS OR RIGHT COWL PANEL HAS BEEN DAMAGED, INSPECT THE MOUNTINGS AND BRACKETS FOR DEFORMATION. IF DAMAGED, THE PRIMARY CRASH SENSOR OR ECS MUST BE REPLACED WHETHER OR NOT THE AIR BAG MODULES HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE PRIMARY CRASH SENSOR MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. NOTE: - The safing sensor is internal to the ECS and is not serviced separately. - If the primary crash sensor is undamaged after a collision, it will automatically reset and can be reused. The SRS contains three sensors located in the following spots: - the ECS, mounted behind the RH cowl side trim panel. - the primary crash sensor mounted on the center radiator support. - the safing sensor, which is internal to the ECS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 1097 Impact Sensor: Service and Repair Removal WARNING: - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, REPLACE THE SENSOR WHETHER OR NOT THE AIR BAG IS DEPLOYED. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: Repair is made by replacement only. If a part is replaced and the new part does not correct the condition install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable(s). 2. Remove the radiator grille. 3. Disconnect the primary crash sensor electrical connector. 4. Remove the primary crash sensor. 1. Remove the screws. 2. Remove the primary crash sensor. Installation WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, REPLACE THE SENSOR WHETHER OR NOT THE AIR BAG IS DEPLOYED. NOTE: Repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 1098 1. Follow the Removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1105 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1106 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1107 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1108 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1109 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 1110 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Replacement, Functional Ignition Switch Lock Cylinder: Service and Repair Replacement, Functional REMOVAL NOTE: The following procedure applies to vehicles that have functional lock cylinders and keys. If key numbers are known, the proper key can be made. 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Position the lock cylinder to RUN. (2) Using a suitable tool, push upward on the cylinder release tab through the hole in the lower shroud while pulling the cylinder outward. INSTALLATION 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Replacement, Functional > Page 1113 Ignition Switch Lock Cylinder: Service and Repair Replacement, Non-Functional REMOVAL NOTE: The following procedure applies to vehicles in which the ignition lock is inoperative and the lock cylinder cannot be rotated due to a lost or broken key, unknown key number, or a cap that has been damaged or broken to the extent that the lock cylinder cannot be rotated. 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 1/8 inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8 inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Replacement, Functional > Page 1114 6. Remove the bearing and the gear. - Thoroughly clean all drill shavings from the steering column and inspect it for damage. INSTALLATION 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. NOTE: Use a new ignition switch lock cylinder. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1118 Neutral Safety Switch: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1119 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair REMOVAL CAUTION: The steering column must be in the locked position, or the lower end of the column wired in such a way that the steering column does not rotate, resulting in damage to the air bag sliding contact. NOTE: Discard the upper intermediate shaft to steering column shaft bolt upon removal. Do not reuse; replace with new bolts. 1. Remove the bolt retaining the upper shaft assembly U-joint to the steering column center shaft. 2. Remove the shock absorber electronic steering sensor. (1) Disconnect the electrical connector. (2) Remove the screws. (3) Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. (1) Remove the steering column lower bearing spring. (2) Remove the sensor ring. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 1125 2. Install the shock absorber electronic steering sensor. (1) Position the shock absorber electronic steering sensor. (2) Install the screws. (3) Connect the electrical connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair REMOVAL CAUTION: The steering column must be in the locked position, or the lower end of the column wired in such a way that the steering column does not rotate, resulting in damage to the air bag sliding contact. NOTE: Discard the upper intermediate shaft to steering column shaft bolt upon removal. Do not reuse; replace with new bolts. 1. Remove the bolt retaining the upper shaft assembly U-joint to the steering column center shaft. 2. Remove the shock absorber electronic steering sensor. (1) Disconnect the electrical connector. (2) Remove the screws. (3) Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. (1) Remove the steering column lower bearing spring. (2) Remove the sensor ring. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Page 1130 2. Install the shock absorber electronic steering sensor. (1) Position the shock absorber electronic steering sensor. (2) Install the screws. (3) Connect the electrical connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation Overdrive Switch: Description and Operation The Transmission Control Switch (TCS) and Transmission Control Indicator Lamp (TCIL) are located inside the end of the gearshift lever. Pushing the TCS will either disengage or engage the overdrive function of the transmission. When overdrive is disengaged, the TCIL will illuminate the word OFF. Each time the ignition switch is placed in the RUN position, the transmission will automatically provide overdrive operation regardless of TCS position the last time the vehicle was running. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Page 1136 Overdrive Switch: Testing and Inspection For testing procedures for the Transmission Control Switch (TCS), please refer to Pinpoint Test C in Automatic Transmission/Transaxle / Testing and Inspection / Procedures / External Control Diagnostics. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Mode Switch: Service and Repair TRANSMISSION MODE SWITCH REMOVAL 1. Remove the Transmission Control (TC) switch. 1. Remove the TC switch cover. 2. Remove the TC switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor .............................................................................................................................................. 8-10 Nm (75-85 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 1143 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 1144 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 1145 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 1146 Transmission Position Switch/Sensor: Service and Repair Special Tools REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1. Remove the bolts. 2. Remove the sensor. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 1147 1. Install the digital transmission range (TR) sensor. 1. Install the sensor. 2. Loosely install the bolts. 2. Install the Digital Transmission Range (TR) Sensor Alignment Tool. NOTE: Make sure that the manual control lever is in the neutral position. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 1148 5. Reconnect the connector. 6. Reconnect the battery ground cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Sensor Transmission Speed Sensor: Locations Output Shaft Speed Sensor Transmission View The Output Shaft Speed Sensor is located under the vehicle, on left side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Sensor > Page 1153 Transmission Speed Sensor: Locations Turbine Speed Sensor The Turbine Shaft Speed Sensor is located under the vehicle, on right side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Page 1154 Output Shaft Speed Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Switch Master Window/Door Lock Control Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Switch > Page 1160 RH Power Door Lock/Window Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Driver Side Power Window Switch: Description and Operation Driver Side The master window regulator control switch is located on the driver side front door trim panel and can be used to activate all of the power windows. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Driver Side > Page 1163 Power Window Switch: Description and Operation Passenger Side A single window regulator control switch is located on the passenger side front door trim panel. This window regulator control switch allows activation of the power window for that door only. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Page 1164 Power Window Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Carefully pry the window regulator switch plate up. 3. Remove the two screws. 4. Carefully pry up and remove the window regulator control switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1169 Windshield Washer Switch: Diagrams Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1170 Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Windshield Washer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1173 Windshield Washer Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1174 Windshield Washer Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1175 Windshield Washer Switch: Component Tests and General Diagnostics Terminals Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1176 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1177 1. Measure the resistance between the multi-function switch terminals. - If the resistances are as specified, the multi-function switch is OK. Return the multi-function switch to the vehicle. Test the system for normal operation. - If the resistances are not as specified, replace the multi-function switch. Test the system for normal operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1178 Windshield Washer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 4. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1179 5. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1183 Wiper Switch: Diagrams Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1184 Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1185 Wiper Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. - Ignition. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis Wiper Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1188 Wiper Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1189 Wiper Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1190 Wiper Switch: Pinpoint Tests Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1191 C1 Part 2 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1192 Part 3 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1193 Wiper Switch: Component Tests and General Diagnostics Terminals Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1194 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1195 1. Measure the resistance between the multi-function switch terminals. - If the resistances are as specified, the multi-function switch is OK. Return the multi-function switch to the vehicle. Test the system for normal operation. - If the resistances are not as specified, replace the multi-function switch. Test the system for normal operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1196 Wiper Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 4. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1197 5. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' Alignment: Customer Interest Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 1207 Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 1208 (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 1209 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 1210 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' Alignment: All Technical Service Bulletins Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 1216 Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 1217 (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 1218 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 1219 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1224 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1225 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1226 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1227 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1228 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1229 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1230 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1231 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1232 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1233 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1234 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1235 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1236 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1237 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1238 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1239 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1240 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1241 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1242 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1243 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1244 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1245 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1246 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1247 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1248 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1249 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1250 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1251 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1252 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1253 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1254 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1255 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1256 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1257 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1258 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1259 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1260 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1261 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1262 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1263 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1264 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1265 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1266 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1267 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1268 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1269 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1270 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1271 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1272 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1273 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1274 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1275 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1276 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1277 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1278 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1279 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1280 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1281 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1282 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1283 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1284 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1285 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1286 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1287 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1288 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1289 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1290 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1291 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1292 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1293 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1294 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1295 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1296 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1297 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1299 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1301 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1302 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1303 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1304 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1305 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1306 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1307 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1308 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1309 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1310 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1311 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1312 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1313 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1314 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1315 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1316 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1317 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1318 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-17-12 > Sep > 98 > Wheel Alignment - Procedures For Incomplete Vehicles Alignment: All Technical Service Bulletins Wheel Alignment - Procedures For Incomplete Vehicles Article No. 98-17-12 09/01/98 ALIGNMENT - ALIGNMENT PROCEDURES FOR INCOMPLETE VEHICLES - SERVICE TIP LIGHT TRUCK: 1998 ECONOLINE ISSUE Wheel alignment on incomplete vehicles is not reimbursable. ACTION After build-up of incomplete vehicles, realign vehicles to factory specification. Setting vehicles to factory specification should resolve all alignment issues. Refer to the following text for details. INCOMPLETE VEHICLES (Cut-Away, Strip Chassis) Wheel alignment on incomplete vehicles (cut-away, strip chassis) is not reimbursable due to installation of special bodies or equipment after the vehicles leave the assembly plant. If readjustment is necessary, follow the instructions in the 1998 Econoline Workshop Manual to reset the alignment back to OEM specification. The cost for such realignment is the responsibility of the final stage manufacturer or modifier. INCOMPLETE VEHICLES (Conversion Vans) On incomplete vehicles (conversion vans), toe must be checked by the final stage manufacturer and is not reimbursable. Should toe readjustment be necessary, follow the instructions in the 1998 Econoline Workshop Manual to reset the alignment to OEM specification. The cost for such realignment is the responsibility of the final stage manufacturer or modifier. Note that occasionally van conversions will require additional adjustments (i.e., caster and camber). If such adjustments are required, they are reimbursable per the Warranty and Policy Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1328 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1329 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1330 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1331 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1332 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1333 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1334 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1335 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1336 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1337 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1338 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1339 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1340 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1341 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1342 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1343 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1344 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1345 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1346 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1347 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1348 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1349 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1351 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1352 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1353 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1354 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1355 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1356 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1357 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1358 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1359 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1360 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1361 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1362 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1363 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1364 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1365 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1366 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1367 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1368 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1369 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1370 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1371 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1372 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1373 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1374 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1375 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1376 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1377 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1378 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1379 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1380 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1381 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1382 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1383 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1384 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1385 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1386 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1387 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1388 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1389 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1390 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1391 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1392 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1393 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1394 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1395 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1396 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1397 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1398 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1399 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1400 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1401 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1402 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1403 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1404 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1405 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1406 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1407 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1408 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1409 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1410 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1411 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1412 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1413 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1414 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1415 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1416 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1417 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1418 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1419 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1420 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1421 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1422 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 98-17-12 > Sep > 98 > Wheel Alignment - Procedures For Incomplete Vehicles Alignment: All Technical Service Bulletins Wheel Alignment - Procedures For Incomplete Vehicles Article No. 98-17-12 09/01/98 ALIGNMENT - ALIGNMENT PROCEDURES FOR INCOMPLETE VEHICLES - SERVICE TIP LIGHT TRUCK: 1998 ECONOLINE ISSUE Wheel alignment on incomplete vehicles is not reimbursable. ACTION After build-up of incomplete vehicles, realign vehicles to factory specification. Setting vehicles to factory specification should resolve all alignment issues. Refer to the following text for details. INCOMPLETE VEHICLES (Cut-Away, Strip Chassis) Wheel alignment on incomplete vehicles (cut-away, strip chassis) is not reimbursable due to installation of special bodies or equipment after the vehicles leave the assembly plant. If readjustment is necessary, follow the instructions in the 1998 Econoline Workshop Manual to reset the alignment back to OEM specification. The cost for such realignment is the responsibility of the final stage manufacturer or modifier. INCOMPLETE VEHICLES (Conversion Vans) On incomplete vehicles (conversion vans), toe must be checked by the final stage manufacturer and is not reimbursable. Should toe readjustment be necessary, follow the instructions in the 1998 Econoline Workshop Manual to reset the alignment to OEM specification. The cost for such realignment is the responsibility of the final stage manufacturer or modifier. Note that occasionally van conversions will require additional adjustments (i.e., caster and camber). If such adjustments are required, they are reimbursable per the Warranty and Policy Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1427 Alignment: By Symptom Technical Service Bulletin # 02-16-8 Date: 020819 Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1428 front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1429 (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1430 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1431 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Technical Service Bulletin # 02-16-8 Date: 020819 Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1432 First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1433 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1434 (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1435 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1436 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Technical Service Bulletin # 98-17-12 Date: 980901 Wheel Alignment - Procedures For Incomplete Vehicles Article No. 98-17-12 09/01/98 ALIGNMENT - ALIGNMENT PROCEDURES FOR INCOMPLETE VEHICLES - SERVICE TIP LIGHT TRUCK: 1998 ECONOLINE ISSUE Wheel alignment on incomplete vehicles is not reimbursable. ACTION After build-up of incomplete vehicles, realign vehicles to factory specification. Setting vehicles to factory specification should resolve all alignment issues. Refer to the following text for details. INCOMPLETE VEHICLES (Cut-Away, Strip Chassis) Wheel alignment on incomplete vehicles (cut-away, strip chassis) is not reimbursable due to installation of special bodies or equipment after the vehicles leave the assembly plant. If readjustment is necessary, follow the instructions in the 1998 Econoline Workshop Manual to reset the alignment back to OEM specification. The cost for such realignment is the responsibility of the final stage manufacturer or modifier. INCOMPLETE VEHICLES (Conversion Vans) On incomplete vehicles (conversion vans), toe must be checked by the final stage manufacturer and is not reimbursable. Should toe readjustment be necessary, follow the instructions in the 1998 Econoline Workshop Manual to reset the alignment to OEM specification. The cost for such realignment is the responsibility of the final stage manufacturer or modifier. Note that occasionally van conversions will require additional adjustments (i.e., caster and camber). If such adjustments are required, they are reimbursable per the Warranty and Policy Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Alignment: Specifications Alignment Camber/Caster Service Adjuster Caster LH ........................................................................................................................................................ ................................................... 4.75° ± 2.75° RH ............................................................................. .............................................................................................................................. 4.75° ± 2.75° Total/Split ............................................................................................................................................. ..................................................... -1.0° ± 0.5° Camber LH ........................................................................................................................................................ ....................................................... 0.5° ± 0.5° RH ............................................................................. .................................................................................................................................. 0.5° ± 0.5° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.5° Toe (Positive Value Is Toe-in, Negative Value Is Toe-out) Total/Split ............................................................................................................................................. .................................................. 0.06° ± 0.25° Dogtracking - Maximum (Centerline of front tires compared to centerline of rear tires) ............................................................................................................................................... 30 mm (1.25 inch) Clear Vision (Negative value is counterclockwise) ............................................................................................................................ .............................................................. 0° ± 3° Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1439 Alignment: Description and Operation WHEEL ALIGNMENT ANGLES Caster and camber correction requirements are factory-determined. Adjusters are available to correct a caster/camber measurement that does not meet specification. Before changing the production caster/camber adjuster, thoroughly inspect the suspension system to locate worn or damaged components that may have caused the setting to change. Negative and Positive Camber 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 and Frame Angle (Positive Caster Shown) CASTER Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Positive Toe (Toe In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1440 Negative Toe TOE The vehicle toe setting: affects tire wear and directional stability. - must be checked after adding aftermarket equipment, such as a snowplow or body. Wheel Track WHEEL TRACK Dogtracking DOGTRACKING 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 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1441 road. SHIMMY 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. 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 (i.e., wind, road camber). 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 readability problem, it is important to understand the difference between wander and poor groove feel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber/Caster Service Adjuster Chart Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber/Caster Service Adjuster Chart > Page 1444 Alignment: Service and Repair Caster and Camber 1. Using an alignment rack and manufacturer's instructions, measure the caster and camber. - Note any difference between the actual measurements and the specification. This information will be used to select the correct service adjuster. CAUTION: Do not bend axles or radius arms to change alignment. 2. Raise and support the front end. 3. Remove the front wheel(s). 4. Check the type and orientation of the installed adjuster. a. Production adjusters have a round flange, a side tab and the amounts of caster and camber stamped in the top of the adjuster. - The first number is the amount of caster; the second number is the amount of camber in degrees if the adjuster is installed in the right-hand axle position. - If the adjuster is in the left-hand axle, the caster number is the opposite sign of the number shown. For example, a positive amount in the right-hand axle is a negative amount in the left axle, and a negative amount in the right-hand is a positive in the left-hand position. b. Service adjusters have a hex flange, no side tab and the adjustment amount of the caster and camber stamped into the top. 5. Select a new service adjuster and its orientation in the axle to obtain the optimum caster/camber. - Note that the caster change or camber change required to obtain the optimum settings must be added to amounts of caster/camber in the old or production adjuster. - Use this example as a guide. If caster must be reduced 1 degree and camber increased +0.75 degree at the LH wheel, and the existing adjuster has +0.25-degree caster as installed, select the 1-degree service adjuster and orient the slot 225 degrees from the straight-ahead position. In all cases, select the adjuster and orientation that will bring the alignment closest to the optimal settings. NOTE: The assembly plant sometimes builds vehicles with adjusters that are not 0-degree type to control alignment. The following chart shows the alignment changes that will occur if the vehicle was originally built with 0-degree adjusters. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber/Caster Service Adjuster Chart > Page 1445 6. Loosen the pinch bolt. Remove the adjuster out of the axle. 7. Install the new service adjuster. Orient the slot as noted in Step 5. (1) Position the new adjuster as specified in the chart. (2) Tighten the pinch bolt. 8. Install the front wheel. 9. Lower the front end. 10. Check the alignment. If not at optimal caster/camber specification, additional adjustment of the rotational orientation of the adjuster is required. 11. Once optimal caster/camber has been achieved, reset the toe and clear vision to optimal settings. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber/Caster Service Adjuster Chart > Page 1446 Alignment: Service and Repair Toe 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings. 4. Loosen the nuts. - Clean and lubricate the steering linkage and tie rod end threads. 5. Rotate the adjusting sleeves to obtain the correct toe setting. 6. Tighten the nuts. Position the RH adjusting sleeve clamp opening downward within 45 degrees of vertical. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber/Caster Service Adjuster Chart > Page 1447 7. Tighten the nuts. Position the LH adjusting sleeve clamp opening upward within 45 degrees of vertical. 8. Recheck the toe settings. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service and Repair Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. - BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. 1. Perform the pre-service procedures. 2. Disconnect the battery ground cable. 3. Remove the (B) fuel pressure relief valve from the (A) fuel injection supply manifold. INSTALLATION 1. Install the fuel pressure relief valve and tighten. 2. Connect the battery ground cable. 3. Perform the post-service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Automatic Transmission Idle Speed: Specifications With Automatic Transmission Hot Idle ................................................................................................................................................ ......................................................... 780 - 810 RPM Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Automatic Transmission > Page 1457 Idle Speed: Specifications With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 780 - 810 RPM Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 REMOVAL 1. Lift the engine air cleaner inlet tube and remove. 2. Unlatch the clamp and remove the air cleaner tray. 3. Remove the air cleaner element. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 EFI/CFI Fuel Pressure Gauge WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the fuel pressure gauge. 2. Slowly open the manual valve on the fuel pressure gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place fuel in a suitable container. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order: 1-6-5-10-2-7-3-8-4-9 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark Plug Gap ................................................................................................................................... ................................... 1.32-1.42 mm (0.052-0.056 in) Spark Plug Torque ......................................... ....................................................................................................................................... 9-20 Nm (7-14 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 1477 Spark Plug: Specifications Torque Spark Plug Gap ................................................................................................................................... ................................... 1.32-1.42 mm (0.052-0.056 in) Spark Plug Torque ......................................... ....................................................................................................................................... 9-20 Nm (7-14 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1478 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................ AWSF22E Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1479 Spark Plug: Service and Repair REMOVAL CAUTION: Mark spark plug locations and return to original location. 1. Remove the ignition coil. 2. Remove the spark plug. 3. Inspect the spark plugs; replace if required. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test Compression Check: Testing and Inspection Compression Test 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly 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 five 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. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test > Page 1485 Compression Check: Testing and Inspection Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating improperly. 3. If two 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 percent of the highest reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test > Page 1486 Compression Check: Testing and Inspection Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification WSS-M2C153-F on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1493 Drive Belt: Description and Operation Part 1 Of 2 Part 2 Of 2 Ford vehicles are equipped with a poly-vee drive belt. To ensure maximum belt life, replacement drive belts must be of the same type and specification as originally installed. The drive belt is tensioned by a spring-loaded tensioner that maintains proper belt tension at all times. A loose drive belt will result in slippage, which can cause a noise complaint or improper accessory operation Generator (GEN) will not charge, etc. An overly tight drive belt will place severe loads on accessory bearings and result in premature drive belt or accessory failure. Refer to the illustrations for the belt routing of each particular engine. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1496 Drive Belt: Component Tests and General Diagnostics Belt Tension The drive belt tensioner automatically adjusts drive belt tension. NOTE: The drive belt tension is not adjustable. Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and can cause the drive belt to come off the drive pulleys. Non-standard replacement drive belts can track differently or improperly. If a replacement drive belt tracks improperly, replace it with an original equipment drive belt to avoid performance failure or loss of belt. When the engine running, check drive belt tracking. If the (A) edge of the drive belt rides beyond the edge of the pulleys, noise and premature wear can occur. Make sure the (B) drive belt rides correctly on the pulley. If a drive belt tracking condition exists, follow the procedures below: - Visually check the drive belt tensioner for damaged, especially the mounting pad surface. If the drive belt tensioner is not installed correctly with the dowels in the mounting bracket holes (4.2L only), the mounting surface pad will be out of position. This will result in chirp and squeal noises. - With the engine running, visually observe the front surface grooves in the pulleys (not the pulley flanges) for excessive wobble. Replace components as required. - Check all accessories, mounting brackets and the drive belt tensioner for any interference preventing the components from mounting properly. Correct any interference condition and recheck belt tracking. - Tighten all accessories, generator mounting brace and drive belt tensioner retaining hardware to specification. Recheck the drive belt tracking. Drive Belt Noise/Flutter Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged pulley of and improperly aligned pulley. To correct, determine the area 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 is an intermittent noise that occurs when the drive belt slips on a pulley during certain conditions, such as engine start-up, rapid engine acceleration or A/C clutch engagement. Drive belt squeal can occur under the following conditions: 1. The A/C discharge pressure goes above specifications, causing one of the following: - The A/C system is overcharged. - The A/C condenser core airflow is blocked. 2. The A/C OFF equalized pressure (the common discharge and suction pressure that occurs after several minutes) exceeds specifications. 3. Any of the accessories are damaged or have a worn or damaged bearing or internal torsional resistance above normal. All accessories must be rotatable by hand in the unloaded condition. If not, inspect the accessory. 4. Fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air conditioning system lubricant. If fluid gets on the drive belt during repairs, clean the drive belt with soap and water, and thoroughly rinse with clean water.The drive belt does not have to be replaced if no apparent damage had occurred. 5. The drive belt is too long. A drive belt that is too long will allow the 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 drive belt tensioner indicator is outside of the wear range window, replace the drive belt. NOTE: The drive belt tensioner arm must rotate freely without binding. 6. The drive belt tensioner is worn or damaged. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1497 Drive Belt Wear V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) Under severe operating conditions (high temperatures, low humidity), drive belt rib cracking can occur at less than 48,000 km (30,000 miles). Drive belt rib cracking had no effect on belt performance. Drive belt "chunking" describes a condition in which the rubber material actually chunks out between the rib cracks. The drive belt must be replaced if chunking occurs. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Lift the engine air cleaner inlet tube and remove. 2. Unlatch the clamp and remove the air cleaner tray. 3. Remove the air cleaner element. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair This model is not equipped with a cabin air filter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair EFI/CFI Fuel Pressure Gauge WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the fuel pressure gauge. 2. Slowly open the manual valve on the fuel pressure gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place fuel in a suitable container. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications TORQUE SPECIFICATIONS Oil Filter ............................................................................................................................................... ........................... 14-17 Nm (125-151.6 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1517 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1518 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1519 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1529 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1530 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1536 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1537 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1538 Heater Hose: Description and Operation A/C Lines And Heater Tubes - Vehicle Underbody, Vans Except RV Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1539 A/C Lines And Heater Tubes - Vehicle Underbody, Vans And Cutaways The auxiliary A/C system uses a rear-mounted heater core which operates in the same manner as the front mounted heater core. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose Heater Hose: Service and Repair Auxillary Heater Hose A/C Lines And Heater Tubes - Vehicle Underbody, Vans Except RV Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose > Page 1542 A/C Lines And Heater Tubes - Vehicle Underbody, Vans And Cutaways OE provides no specific replacement procedure for these hoses. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose > Page 1543 Heater Hose: Service and Repair Heater Hose Couplings Heater Hose Disconnect Tool SPECIAL TOOL(S) DISCONNECT 1. Depressurize the engine cooling system. WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. Push the Heater Hose Disconnect Tool over the coupling retainer windows to compress the retainer locking tabs. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Tool must be perpendicular to and on the highest point of the coupling. 4. Pull the heater water hose away from the heater core tube. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose > Page 1544 7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer. CONNECT 1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. 2. Install a new coupling retainer, spacer, and lubricated O-rings into the quick disconnect coupling housing. 3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose > Page 1545 Heater Hose: Service and Repair Removal and Installation REMOVAL 1. Drain the cooling system. 2. Disconnect the quick disconnect heater hose couplings at the heater core. 3. Remove the engine cover. 4. Disconnect the supply heater water hose at the engine. 5. Disconnect the return heater water hose at the engine. 6. Disconnect the quick disconnect heater hose couplings from the heater water hoses. NOTE: This step must be performed if the vehicle is equipped with an auxiliary A/C-heater system. 7. Remove the heater water hoses. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose > Page 1546 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Page 1547 Heater Hose Disconnect Tool Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications A/C Liquid Jumper Line ....................................................................................................................... ........................................... 14-20 N.m (10-15 Lb/Ft) Compressor Discharge Line ............................................................................................................................................................ 35-42 N.m (26-31 Lb/Ft) Compressor Suction Line ............................................................................. ................................................................................... 43-51 N.m (32-37 Lb/Ft) Evaporator Discharge Line .............................................................................................................................................................. 35-42 N.m (26-31 Lb/Ft) Inlet Line ...................................................................................................... ................................................................................... 21-27 N.m (15-20 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 1551 Hose/Line HVAC: Description and Operation NOTE: Whenever a refrigerant line is replaced, it is also necessary to replace the suction accumulator/drier. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the following features: - the upstream side contains low pressure refrigerant gas. - the downstream side contains high pressure refrigerant gas. - a serviceable high pressure A/C charge port valve is located on the downstream side. - the downstream side also contains a fitting used to mount the A/C pressure cut-off switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cut-off switch can be removed without discharging the A/C system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line Hose/Line HVAC: Service and Repair A/C Hose/Line Auxiliary A/C-Heater System REMOVAL 1. Using proper procedures, recover the refrigerant. 2. Disconnect the battery ground cable. 3. Partially drain the engine cooling system. 4. Remove the engine air cleaner (ACL) and the air cleaner outlet tube. 5. Disconnect the condenser core refrigerant lines. 1. Disconnect the compressor discharge line. 2. Disconnect the condenser to evaporator tube. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 6. Disconnect the A/C evaporator core fitting. 1. Remove the screw. 2. Disconnect the A/C evaporator core fitting. 7. Remove the four clamps. 1. Remove the screw. 2. Remove the clamp. 8. Raise the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1554 9. Disconnect the underbody tube spring lock coupling. 10. Lower the vehicle. 11. Remove the condenser to evaporator tubes. INSTALLATION 1. Service the replacement condenser to evaporator tube with the proper amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Route the condenser to evaporator tube. 3. Raise the vehicle. 4. Connect the underbody tube spring lock coupling. 5. Lower the vehicle. 6. Connect tile A/C evaporator core fitting. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the A/C evaporator core fitting. 3. Install the screw. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1555 7. Connect the condenser core refrigerant lines. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the condenser to evaporator tube. 3. Connect the compressor discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 8. Install the four clamps. 1. Install the clamp. 2. Install the screw. 9. Install the engine air cleaner and the air cleaner outlet tube. 10. Fill the engine cooling system. 11. Reconnect the battery ground cable. 12. Using proper procedures, evacuate and charge the A/C system. See: Heating and Air Conditioning/Service and Repair/Evacuation and Charging Standard A/C REMOVAL 1. Using proper procedures, recover the refrigerant. 2. Disconnect the battery ground cable. 3. Remove the engine Air Cleaner (ACL) and the air cleaner outlet tube. 4. Disconnect the condenser core refrigerant lines. 1. Disconnect the compressor discharge line. 2. Disconnect the condenser to evaporator tube. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1556 5. Disconnect the A/C evaporator core fitting. 1. Remove the screw. 2. Disconnect the A/C evaporator core fitting. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 6. Remove the condenser to evaporator tube. INSTALLATION 1. Service the replacement condenser to evaporator tube with the proper amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Route the condenser to evaporator tube. 3. Connect the A/C evaporator core fitting. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the A/C evaporator core fitting. 3. Install the screw. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 4. Connect the condenser core refrigerant lines. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the condenser to evaporator tube. 3. Connect the compressor discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1557 5. Install the engine air cleaner and the air cleaner outlet tube. 6. Reconnect the battery ground cable. 7. Using proper procedures, evacuate and charge the A/C system. See: Heating and Air Conditioning/Service and Repair/Evacuation and Charging Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1558 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Auxiliary A/C Refrigeration Line REMOVAL 1. Remove the condenser to evaporator tube. 2. Disconnect the suction accumulator/drier spring lock coupling. 3. Disconnect the compressor suction line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 4. Remove the four clamps. 1. Remove the screw. 2. Remove the clamp. 5. Raise the vehicle. 6. Disconnect the underbody tube spring lock coupling. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1559 7. Lower the vehicle. 8. Remove the auxiliary A/C refrigeration line. INSTALLATION 1. Service the replacement auxiliary A/C refrigeration line with the proper amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Route the auxiliary A/C refrigeration line. 3. Raise and support the vehicle. 4. Connect the underbody tube spring lock coupling. 5. Lower the vehicle. 6. Connect the compressor suction line. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the compressor suction line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 7. Connect the suction accumulator/drier spring lock coupling. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1560 8. Install the four clamps. 1. Install the clamp. 2. Install the screw. 9. Install the condenser to evaporator tube. Auxiliary A/C-Heater System REMOVAL 1. Using proper procedures, recover the refrigerant. 2. Disconnect the battery ground cable. 3. Partially drain the engine cooling system. 4. Remove the engine air cleaner (ACL) and the air cleaner outlet tube. 5. Disconnect the condenser core refrigerant lines. 1. Disconnect the compressor discharge line. 2. Disconnect the condenser to evaporator tube. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 6. Disconnect the A/C evaporator core fitting. 1. Remove the screw. 2. Disconnect the A/C evaporator core fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1561 7. Remove the four clamps. 1. Remove the screw. 2. Remove the clamp. 8. Raise the vehicle. 9. Disconnect the underbody tube spring lock coupling. 10. Lower the vehicle. 11. Remove the condenser to evaporator tubes. INSTALLATION 1. Service the replacement condenser to evaporator tube with the proper amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Route the condenser to evaporator tube. 3. Raise the vehicle. 4. Connect the underbody tube spring lock coupling. 5. Lower the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1562 6. Connect tile A/C evaporator core fitting. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the A/C evaporator core fitting. 3. Install the screw. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 7. Connect the condenser core refrigerant lines. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the condenser to evaporator tube. 3. Connect the compressor discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 8. Install the four clamps. 1. Install the clamp. 2. Install the screw. 9. Install the engine air cleaner and the air cleaner outlet tube. 10. Fill the engine cooling system. 11. Reconnect the battery ground cable. 12. Using proper procedures, evacuate and charge the A/C system. See: Heating and Air Conditioning/Service and Repair/Evacuation and Charging Standard A/C REMOVAL 1. Using proper procedures, recover the refrigerant. 2. Disconnect the battery ground cable. 3. Remove the engine Air Cleaner (ACL) and the air cleaner outlet tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1563 4. Disconnect the condenser core refrigerant lines. 1. Disconnect the compressor discharge line. 2. Disconnect the condenser to evaporator tube. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 5. Disconnect the A/C evaporator core fitting. 1. Remove the screw. 2. Disconnect the A/C evaporator core fitting. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 6. Remove the condenser to evaporator tube. INSTALLATION 1. Service the replacement condenser to evaporator tube with the proper amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Route the condenser to evaporator tube. 3. Connect the A/C evaporator core fitting. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the A/C evaporator core fitting. 3. Install the screw. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1564 4. Connect the condenser core refrigerant lines. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the condenser to evaporator tube. 3. Connect the compressor discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 5. Install the engine air cleaner and the air cleaner outlet tube. 6. Reconnect the battery ground cable. 7. Using proper procedures, evacuate and charge the A/C system. See: Heating and Air Conditioning/Service and Repair/Evacuation and Charging Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Page 1565 Hose/Line HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications TORQUE SPECIFICATIONS Pressure Hose Fitting .......................................................................................................................... ....................................... 17-23 Nm (13-17 ft. lbs.) Pressure Hose At Steering Gear ................................................................................................................................................. 17-23 Nm (13-17 ft. lbs.) Return Hose Fitting At Steering Gear ........................................................................................................................................ 17-23 Nm (13-17 ft. lbs.) Power Steering Metal Line Retainer Nuts .................................................................................................................................. 15-17 Nm (11-13 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 1569 Power Steering Line/Hose: Service and Repair 1. When connecting a fitting with a seal ring, the ring must be replaced. - The Seal Replacer is used to install the return line connector seal and the pressure line connector seal. 2. Fill and leak check the system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 1570 Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing Brake Fluid: Customer Interest Steering/Brakes - Brake Pedal Kick-Back/Grabbing TSB 07-11-10 06/11/07 BRAKE PEDAL KICKBACK OR GRABBING FORD: 1997-2007 E-Series 1999-2008 F-Super Duty 2000-2005 Excursion This article supersedes TSB 99-25-8 to update the vehicle model years. ISSUE Some 1999-2008 F-Super Duty, 2000-2005 Excursion, and 1997-2007 E-Series vehicles equipped with Hyrdo-Boost(R) brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes. This may be caused by contamination within the power steering system. ACTION Filter the power steering fluid by installing a temporary filter in the power steering system. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Verify that the line from the pump and the line to the gear at the Hydro-Boost(R) are in their correct orientation (and not crossed). The passenger side goes to the pump, the driver side goes to the gear. 2. Attach a pinch-off clamp to the lower power steering hose approximately 6" (15 cm) from the lower port of the power steering cooler to keep fluid from emptying out of the system when the hose is disconnected. 3. Disconnect the power steering hose from the lower port on the cooler. Cap the cooler port to minimize fluid leakage and immediately install the temporary filter in line with the power steering hose using hose clamps to retain the filter (the filter needs to go in the low pressure line that goes from gear to cooler to reservoir, where it would be most accessible). 4. Attach the other end of the filter to the cooler using the clamps provided. 5. Remove the pinch-off clamp from the power steering hose. FILTERING PROCEDURE CAUTION BE SURE THAT THE PARKING BRAKE IS APPLIED DURING THE FOLLOWING STEPS 1-7. 1. Check power steering fluid level before starting the vehicle. 2. Start the vehicle and allow it to idle for approximately 15 seconds. NOTE DO NOT HOLD THE STEERING AT LOCK FOR MORE THAN 5 SECONDS. 3. Turn steering wheel lock-to-lock 10 times. 4. Pump service brake pedal hard to floor 25 times. 5. Turn steering wheel lock-to-lock 5 times. 6. Remove the filter and reconnect the power steering line to the cooler. Discard the filter. Fill the power steering system. Refer to Workshop Manual (WSM), Section 211-00 Power Steering System Filling. 7. With the engine at idle, gradually apply the brake pedal until fully applied. If the brake pedal kickback persists, replace the Hydro-Boost(R) brake booster. Refer to WSM, Section 206-07. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing > Page 1580 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 MTO71110 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 2005 07 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing Brake Fluid: All Technical Service Bulletins Steering/Brakes - Brake Pedal Kick-Back/Grabbing TSB 07-11-10 06/11/07 BRAKE PEDAL KICKBACK OR GRABBING FORD: 1997-2007 E-Series 1999-2008 F-Super Duty 2000-2005 Excursion This article supersedes TSB 99-25-8 to update the vehicle model years. ISSUE Some 1999-2008 F-Super Duty, 2000-2005 Excursion, and 1997-2007 E-Series vehicles equipped with Hyrdo-Boost(R) brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes. This may be caused by contamination within the power steering system. ACTION Filter the power steering fluid by installing a temporary filter in the power steering system. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Verify that the line from the pump and the line to the gear at the Hydro-Boost(R) are in their correct orientation (and not crossed). The passenger side goes to the pump, the driver side goes to the gear. 2. Attach a pinch-off clamp to the lower power steering hose approximately 6" (15 cm) from the lower port of the power steering cooler to keep fluid from emptying out of the system when the hose is disconnected. 3. Disconnect the power steering hose from the lower port on the cooler. Cap the cooler port to minimize fluid leakage and immediately install the temporary filter in line with the power steering hose using hose clamps to retain the filter (the filter needs to go in the low pressure line that goes from gear to cooler to reservoir, where it would be most accessible). 4. Attach the other end of the filter to the cooler using the clamps provided. 5. Remove the pinch-off clamp from the power steering hose. FILTERING PROCEDURE CAUTION BE SURE THAT THE PARKING BRAKE IS APPLIED DURING THE FOLLOWING STEPS 1-7. 1. Check power steering fluid level before starting the vehicle. 2. Start the vehicle and allow it to idle for approximately 15 seconds. NOTE DO NOT HOLD THE STEERING AT LOCK FOR MORE THAN 5 SECONDS. 3. Turn steering wheel lock-to-lock 10 times. 4. Pump service brake pedal hard to floor 25 times. 5. Turn steering wheel lock-to-lock 5 times. 6. Remove the filter and reconnect the power steering line to the cooler. Discard the filter. Fill the power steering system. Refer to Workshop Manual (WSM), Section 211-00 Power Steering System Filling. 7. With the engine at idle, gradually apply the brake pedal until fully applied. If the brake pedal kickback persists, replace the Hydro-Boost(R) brake booster. Refer to WSM, Section 206-07. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing > Page 1586 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 MTO71110 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 2005 07 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Fluid: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: All Technical Service Bulletins Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Fluid: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 1592 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Fluid: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 1593 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Fluid: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 1599 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Fluid: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 1600 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1601 Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. High Performance DOT3 Brake Fluid Ford Specification ESA-M6C25-A Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Service Precautions > Technician Safety Information Brake Fluid: Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Service Precautions > Technician Safety Information > Page 1604 Brake Fluid: Vehicle Damage Warnings Clean, fresh Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A is the only brake fluid that should be used in Ford vehicles. - Do not reuse brake fluid drained or bled from the system. - Do not use brake fluid that has been stored in an open container. - Do not use contaminated brake fluid. - Do not mix different types of brake fluid. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity 30.6 qts .............................................................................................................................................................. ....................................... Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1609 Coolant: Fluid Type Specifications COOLANT TYPE Ethylene Glycol (EC) .............................................................................................................................................................. ........... Coolant Mixture with Water 50% .............................................................................................................................................................. ........................ Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolant type. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 1614 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 1615 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications With E4OD Transmission A/T Fluid 4x2 ....................................................................................................................................... ........................................................... 15L (15.9 Qt) A/T Fluid 4x4 ....................................................................................................................................... ........................................................ 15.5L (16.4 Qt) NOTE: With engine at operating temperature, shift through all gears. Check fluid in PARK add fluid as needed. With 4R70W Transmission A/T Fluid .............................................................................................................................................. ......................................................... 13.1L (13.9 Qt) NOTE: With engine at operating temperature, shift through all gears. Check fluid in PARK add fluid as needed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1618 Fluid - A/T: Fluid Type Specifications E4OD Fluid Type ............................................................................................................................................ ............................................... MERCON(R) V ATF 4R70W Fluid Type ............................................................................................................................................ ............................................... MERCON(R) V ATF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1619 Fluid - A/T: Diagrams PARK Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1620 PARK Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1621 PARK Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1622 PARK Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1623 2 ND GEAR Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1624 2 ND GEAR Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1625 TCC RELEASE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1626 TCC RELEASE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1627 LINE/SRV PRESSURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1628 PARK NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1629 PARK NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1630 1ST GEAR NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1631 2ND GEAR NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1632 3RD GEAR NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1633 4TH GEAR NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1634 MANUAL 3RD GEAR NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1635 MANUAL 2ND GEAR NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1636 MANUAL 1ST GEAR NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1637 Fluid - A/T: Service and Repair REMOVAL 1. Disconnect the battery. WARNING: ON VEHICLES EQUIPPED WITH AN AUXILIARY BATTERY, BOTH THE NEGATIVE AND POSITIVE BATTERY CABLES MUST BE DISCONNECTED. WARNING: ON VEHICLES EQUIPPED WITH A 7.3L ENGINE, BOTH THE PRIMARY AND SECONDARY BATTERIES MUST BE DISCONNECTED. 2. Raise and support the vehicle. 3. Disconnect the connector. 4. Remove the transmission fluid pan and the gasket. 1. Loosen, but do not remove, the bolts. 2. Remove the front and side bolts. 3. Lower the front of the fluid pan and allow the fluid to drain. 4. Remove the remaining bolts and the fluid pan. NOTE: Do not discard the gasket unless damaged. This is a reusable gasket. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1638 5. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary. CAUTION: When replacing the transmission fluid and filter and seal assembly, the torque converter, transmission cooler, cooler lines and Cooler Bypass Valve (CBV) must be thoroughly flushed to remove any contamination. NOTE: After removal, discard the filter and seal assembly. 6. If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore. CAUTION: Be careful not to scratch or damage the aluminum bore. The new seal may leak. 7. On all except vehicles equipped with a 7.3L engine, remove the torque converter drain plug cover. 8. On vehicles equipped with the 7.3L engine, remove the 5 (A) bolts and the (B) flywheel inspection cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1639 9. With a drain pan properly positioned, remove and discard the torque converter drain plug. Allow the fluid to drain. NOTE: The 7.3L engine-style transmission case is shown, others are similar. 10. Flush the fluid cooler and fluid cooler lines. INSTALLATION 1. After the torque converter has drained, install a new drain plug. NOTE: The 7.3L engine-style transmission case is shown, others are similar. 2. On all except vehicles equipped with a 7.3L engine, install the torque converter drain plug cover. 3. On vehicles equipped with the 7.3L engine, install the (A) flywheel inspection cover and the 5 (B) bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1640 4. Select the appropriate (A) 4x2-style or (B) 4x4-style filter assembly and transmission pan. CAUTION: Mixing (A) 4x2-style and (B) 4x4-style transmission fluid filters and transmission pan assembly components can cause transmission damage. 5. Press the fluid filter and seal assembly into the pump bore until seated. NOTE: Prior to installation, lightly lubricate the seal with clean MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. 6. Position the (A) gasket onto the cleaned fluid pan. Make sure the (B) magnet is positioned over the dimple in the fluid pan. NOTE: Do not discard the gasket unless damaged. This is a reusable gasket. NOTE: Apply a light coat of petroleum jelly to hold the gasket to the fluid pan. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1641 7. Install the (A) pan with gasket. Alternately tighten the (B) bolts. 8. Connect the connector. 9. Remove the supports and lower the vehicle. 10. Connect the battery ground cable. 11. Refill the transmission. 1. Add 6.2 liters (6.5 quarts) of MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent transmission fluid to the transmission through the fluid filler tube. 2. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements. 3. Check and adjust the transmission fluid, in 0.24 liter (0.5 pint) increments, to the proper level (cross-hatched area of the fluid level indicator at normal operating temperature. CAUTION: Use only MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. The use of any other fluids can result in the transmission failing to operate in a normal manner or failure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Dana 60-1U ......................................................................................................................................... ......................................................................... 6.3 pt. Dana 70 ............................................................................................................................................... ......................................................................... 6.5 pt. Dana 70HD .......................................................................................................................................... ........................................................................ 7.5 pt. Ford 8.8 inch ........................................................................................................................................ ........................................................................ 5.5 pt. Ford 9.75 inch ...................................................................................................................................... ........................................................................ 5.5 pt. Note: Fill to 1/4 to 9/16 inch below fill hole. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1646 Fluid - Differential: Fluid Type Specifications Standard .............................................................................................................................................. .......................................... Synthetic 75W-140 GL-5 Limited Slip .......................................................................................................................................... ...................................... Synthetic 75W-140 GL-5+ Note: Part no. XY-75W140-QL Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1651 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1652 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1653 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1654 Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 5.7L (6.0 Qt) NOTE: Listed capacities are approximate. Check fluid level after filling. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1657 Engine Oil: Fluid Type Specifications Engine Oil Type Type ..................................................................................................................................................... .......................................................................... GF-3 Viscosity .............................................................................................................................................. ...................................................................... 5W-20 NOTE: Must meet Ford Specification WSS-M2C-153-H Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing Power Steering Fluid: Customer Interest Steering/Brakes - Brake Pedal Kick-Back/Grabbing TSB 07-11-10 06/11/07 BRAKE PEDAL KICKBACK OR GRABBING FORD: 1997-2007 E-Series 1999-2008 F-Super Duty 2000-2005 Excursion This article supersedes TSB 99-25-8 to update the vehicle model years. ISSUE Some 1999-2008 F-Super Duty, 2000-2005 Excursion, and 1997-2007 E-Series vehicles equipped with Hyrdo-Boost(R) brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes. This may be caused by contamination within the power steering system. ACTION Filter the power steering fluid by installing a temporary filter in the power steering system. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Verify that the line from the pump and the line to the gear at the Hydro-Boost(R) are in their correct orientation (and not crossed). The passenger side goes to the pump, the driver side goes to the gear. 2. Attach a pinch-off clamp to the lower power steering hose approximately 6" (15 cm) from the lower port of the power steering cooler to keep fluid from emptying out of the system when the hose is disconnected. 3. Disconnect the power steering hose from the lower port on the cooler. Cap the cooler port to minimize fluid leakage and immediately install the temporary filter in line with the power steering hose using hose clamps to retain the filter (the filter needs to go in the low pressure line that goes from gear to cooler to reservoir, where it would be most accessible). 4. Attach the other end of the filter to the cooler using the clamps provided. 5. Remove the pinch-off clamp from the power steering hose. FILTERING PROCEDURE CAUTION BE SURE THAT THE PARKING BRAKE IS APPLIED DURING THE FOLLOWING STEPS 1-7. 1. Check power steering fluid level before starting the vehicle. 2. Start the vehicle and allow it to idle for approximately 15 seconds. NOTE DO NOT HOLD THE STEERING AT LOCK FOR MORE THAN 5 SECONDS. 3. Turn steering wheel lock-to-lock 10 times. 4. Pump service brake pedal hard to floor 25 times. 5. Turn steering wheel lock-to-lock 5 times. 6. Remove the filter and reconnect the power steering line to the cooler. Discard the filter. Fill the power steering system. Refer to Workshop Manual (WSM), Section 211-00 Power Steering System Filling. 7. With the engine at idle, gradually apply the brake pedal until fully applied. If the brake pedal kickback persists, replace the Hydro-Boost(R) brake booster. Refer to WSM, Section 206-07. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing > Page 1666 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 MTO71110 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 2005 07 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing Power Steering Fluid: All Technical Service Bulletins Steering/Brakes - Brake Pedal Kick-Back/Grabbing TSB 07-11-10 06/11/07 BRAKE PEDAL KICKBACK OR GRABBING FORD: 1997-2007 E-Series 1999-2008 F-Super Duty 2000-2005 Excursion This article supersedes TSB 99-25-8 to update the vehicle model years. ISSUE Some 1999-2008 F-Super Duty, 2000-2005 Excursion, and 1997-2007 E-Series vehicles equipped with Hyrdo-Boost(R) brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes. This may be caused by contamination within the power steering system. ACTION Filter the power steering fluid by installing a temporary filter in the power steering system. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Verify that the line from the pump and the line to the gear at the Hydro-Boost(R) are in their correct orientation (and not crossed). The passenger side goes to the pump, the driver side goes to the gear. 2. Attach a pinch-off clamp to the lower power steering hose approximately 6" (15 cm) from the lower port of the power steering cooler to keep fluid from emptying out of the system when the hose is disconnected. 3. Disconnect the power steering hose from the lower port on the cooler. Cap the cooler port to minimize fluid leakage and immediately install the temporary filter in line with the power steering hose using hose clamps to retain the filter (the filter needs to go in the low pressure line that goes from gear to cooler to reservoir, where it would be most accessible). 4. Attach the other end of the filter to the cooler using the clamps provided. 5. Remove the pinch-off clamp from the power steering hose. FILTERING PROCEDURE CAUTION BE SURE THAT THE PARKING BRAKE IS APPLIED DURING THE FOLLOWING STEPS 1-7. 1. Check power steering fluid level before starting the vehicle. 2. Start the vehicle and allow it to idle for approximately 15 seconds. NOTE DO NOT HOLD THE STEERING AT LOCK FOR MORE THAN 5 SECONDS. 3. Turn steering wheel lock-to-lock 10 times. 4. Pump service brake pedal hard to floor 25 times. 5. Turn steering wheel lock-to-lock 5 times. 6. Remove the filter and reconnect the power steering line to the cooler. Discard the filter. Fill the power steering system. Refer to Workshop Manual (WSM), Section 211-00 Power Steering System Filling. 7. With the engine at idle, gradually apply the brake pedal until fully applied. If the brake pedal kickback persists, replace the Hydro-Boost(R) brake booster. Refer to WSM, Section 206-07. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing > Page 1672 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 MTO71110 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 2005 07 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 07-1-7 > Jan > 07 > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 07-1-7 > Jan > 07 > Steering - Mercon V(R) Fluid Usage > Page 1677 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 07-1-7 > Jan > 07 > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 07-1-7 > Jan > 07 > Steering - Mercon V(R) Fluid Usage > Page 1683 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Fill to line in power steering fluid reservoir. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1686 Power Steering Fluid: Fluid Type Specifications FLUID TYPE ........................................................................................................................................................... Ford E6AZ-19582-AA or equivalent Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1691 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1692 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1693 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1694 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1695 Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1696 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1697 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1698 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity Without Auxiliary .................................................................................................................................. ................................................... 1.47 kg (52 oz) With Auxiliary .......................................................... ................................................................................................................................ 1.81 kg (64 oz) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1701 Refrigerant: Fluid Type Specifications Refrigerant Type................................................................................................................................... ............................ R-134a YN-19 WSH-M17B19-A Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITY Without Auxiliary .................................................................................................................................. ...................................................... 266 ml (9 oz) With Auxiliary .......................................................... ................................................................................................................................. 384 ml (13 oz) REFRIGERANT OIL ADDING CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. NOTE: Service A/C compressors are shipped without compressor oil. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. ^ If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. ^ If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. ^ If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) (Motorcraft YN-12-C), F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. ^ Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcract YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. 4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when carrying out each of the following repairs: ^ installation of a new A/C evaporator core orifice ^ installation of a new A/C compressor pressure relief valve ^ installation of a new refrigerant line ^ repair of an O-ring seal leak ^ repair of a charge port leak 6. Installation of new components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1706 Refrigerant Oil: Fluid Type Specifications PAG Oil (R-134a Systems) ...................................................................................................... F7AZ-19589-DA (Motorcraft YN-12-C) WSH-M1C231-B Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure Brake Bleeding: Service and Repair Caliper Bleeding Procedure 1. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. 2. Have an assistant pump the brake pedal (BP) and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1711 Brake Bleeding: Service and Repair Manual Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Place a box end wrench on the RH rear 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 brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear bleeder screw. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1712 6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw. 7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front disc brake caliper bleeder screw. 11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1713 Brake Bleeding: Service and Repair Master Cylinder Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 any part of the hydraulic system has been disconnected for repair or replacement, air can enter the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. - When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines. 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir, and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 4. Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 5. If the brake master cylinder is being primed at the bench, install it in the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1714 6. Remove the short brake tubes, and install the brake outlet tubes. 7. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal. 2 Loosen the rearmost brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten 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 at the front brake tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1715 Brake Bleeding: Service and Repair Pressure Bleeding 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 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 3. Place a box end wrench on the RH rear 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 brake fluid. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1716 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS) NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been replaced or if the HCU lines have been opened. 1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 2. Connect a clear waste line to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 3. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear bleeder screw, and disconnect the waste line. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1717 5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw, in that order. 6. Connect the NGS DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the NGS instructions. 7. Repeat the system bleed procedure as outlined in Steps 1 through 5. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect the battery ground cable(s). WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable(s). REACTIVATION PROCEDURE 1. Disconnect the battery ground cables. WARNING: THE AIR BAG SIMULATORS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Reconnect the passenger air bag module. 7. Reconnect the battery ground cable(s). 8. Prove out the system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 1722 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the primary crash sensor connected and mounted to the vehicle? [ ] 2. Is the three-way connector at the base of the steering column connected? [ ] 3. Are the air bag modules and belt and buckle assembly pretensioners or air bag simulators connected? [ ] 4. Is the air bag Electronic Crash Sensor (ECS) module connected? [ ] 5. Is the vehicle battery connected? [ ] Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1728 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1729 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1730 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1731 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1732 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1733 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1734 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1735 Fuse: Electrical Diagrams Fuse 4 Fuse 4 - protects the following circuits: - PCM Keep Alive Memory - Instrument Cluster Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1736 Fuse 8 Fuse 8 - protects the following circuits: - Instrument Panel (I/P) Fuse 4 - I/P Fuse 5 - I/P Fuse 10 - I/P Fuse 11 - I/P Fuse 16 - I/P Fuse 22 - I/P Fuse 23 - I/P Fuse 28 - I/P Fuse 38 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1737 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - PCM Power Relay - Engine Compartment Fuse 4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1738 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Auxiliary Battery Relay - Engine Compartment Fuse 14 - Engine Compartment Fuse 22 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1739 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: - Engine Compartment Fuse 26 - Engine Compartment Fuse 27 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1740 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Blower Motor Relay - Blower Motor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1741 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: - Trailer Running Lamps - Trailer Backup Lamps Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1742 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - Main Light Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1743 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1744 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Auxiliary Blower Motor Relay - Remote Keyless Entry Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1745 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Fuel Pump Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1746 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Instrument Panel (I/P) Fuse 40 - I/P Fuse 41 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - 4 Wheel Anti-Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: - Electric Brake Controller Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: - Modified Vehicle Power Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: - Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1751 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: - Ignition Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1752 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1753 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: - Daytime Running Lamp Module - Horn Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1755 Power Distribution Fuse 1 Fuse 1 - protects the following circuits: - Rear Anti-Lock Brakes System Module - 4 Wheel Anti-Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1756 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1757 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: - Brake Warning Diode/Resistor - Instrument Cluster - Warning Chime - 4 Wheel Anti-Lock Brakes System Relay - Warning Indicators Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1758 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1759 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: - Main Light Switch - Remote Keyless Entry Module - Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Power Locks (With Remote Keyless Entry) - Illuminated Entry - Warning Chime - Modified Vehicle - Power Mirrors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 - Main Light Switch - Courtesy Lamps Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1765 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1766 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1769 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Remote Keyless Entry Module - Power Lock Switches - Memory Lock Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1770 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1771 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Shift Interlock - Speed Control - Daytime Running Lamps Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1772 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1773 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Multi-Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1774 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1775 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Radio Capacitor - Ignition Coil - PCM Diode - PCM Power Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1776 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1777 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1778 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1779 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - Wiper Control Module - Windshield Wiper Motor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1780 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1781 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Main Light Switch (External lamps) - Multi-Function Switch (Flash-to-pass) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1782 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1783 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1784 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1785 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Brake Pressure Switch - Brake Pedal Position Sensor - Multi-Function Switch (Hazards) - Rear Anti-Lock Brakes System Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1786 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1787 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1788 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: - Transmission Range Sensor - Auxiliary Battery Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1789 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1790 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Blend Door Actuator - Selector Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1791 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1792 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: - Instrument Cluster (Air Bag and Charge Indicator) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1793 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1794 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1795 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1796 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Power Seats Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1797 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - Air Bag Diagnostic Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1798 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1799 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: - Overdrive Cancel Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1800 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1801 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: - Power Windows Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1802 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1803 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: - Memory Power Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1804 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: - Cigar Lighter - Data Link Connector Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1805 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1806 Power Distribution Fuse 24 Fuse 24 - protects the following circuits: - Illuminated Entry Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1807 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1808 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: - Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1809 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1810 Power Distribution Fuse 28 Fuse 28 - protects the following circuits: - Power Plug Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1811 Power Distribution Fuse 34 Fuse 34 - protects the following circuits: - Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1812 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1813 Power Distribution Fuse 36 Fuse 36 - protects the following circuits: - Cluster - Radio - Steering Column Assembly Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1814 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1815 Power Distribution Fuse 38 Fuse 38 - protects the following circuits: - Air Bag Diagnostic Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1816 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1817 Power Distribution Fuse 40 Fuse 40 - protects the following circuits: - Modified Vehicle Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1818 Power Distribution Fuse 41 Fuse 40 - protects the following circuits: - Modified Vehicle Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1819 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1824 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1825 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1826 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1827 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1828 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1829 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1830 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1831 Fuse Block: Electrical Diagrams Engine Compartment Fuse Box (Part 1 Of 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1832 Engine Compartment Fuse Box (Part 2 Of 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1833 Instrument Panel Fuse Panel (Part 1 Of 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1834 Instrument Panel Fuse Panel (Part 2 Of 2) Fuse 4 Fuse 4 - protects the following circuits: - PCM Keep Alive Memory - Instrument Cluster Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1835 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Instrument Panel (I/P) Fuse 4 - I/P Fuse 5 - I/P Fuse 10 - I/P Fuse 11 - I/P Fuse 16 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1836 - I/P Fuse 22 - I/P Fuse 23 - I/P Fuse 28 - I/P Fuse 38 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1837 - PCM Power Relay - Engine Compartment Fuse 4 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Auxiliary Battery Relay - Engine Compartment Fuse 14 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1838 - Engine Compartment Fuse 22 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: - Engine Compartment Fuse 26 - Engine Compartment Fuse 27 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1839 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Blower Motor Relay - Blower Motor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1840 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: - Trailer Running Lamps - Trailer Backup Lamps Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1841 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - Main Light Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1842 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1843 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Auxiliary Blower Motor Relay - Remote Keyless Entry Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1844 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Fuel Pump Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1845 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Instrument Panel (I/P) Fuse 40 - I/P Fuse 41 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1846 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - 4 Wheel Anti-Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1847 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: - Electric Brake Controller Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1848 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: - Modified Vehicle Power Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1849 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: - Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1850 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: - Ignition Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1851 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1852 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: - Daytime Running Lamp Module - Horn Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1853 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1854 Power Distribution Fuse 1 Fuse 1 - protects the following circuits: - Rear Anti-Lock Brakes System Module - 4 Wheel Anti-Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1855 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1856 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: - Brake Warning Diode/Resistor - Instrument Cluster - Warning Chime - 4 Wheel Anti-Lock Brakes System Relay - Warning Indicators Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1857 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1858 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: - Main Light Switch - Remote Keyless Entry Module - Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1859 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1860 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1861 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Power Locks (With Remote Keyless Entry) - Illuminated Entry - Warning Chime - Modified Vehicle - Power Mirrors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1862 - Main Light Switch - Courtesy Lamps Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1863 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1864 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1865 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1866 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1867 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1868 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Remote Keyless Entry Module - Power Lock Switches - Memory Lock Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1869 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1870 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Shift Interlock - Speed Control - Daytime Running Lamps Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1871 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1872 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Multi-Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1873 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1874 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Radio Capacitor - Ignition Coil - PCM Diode - PCM Power Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1875 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1876 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1877 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1878 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - Wiper Control Module - Windshield Wiper Motor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1879 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1880 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Main Light Switch (External lamps) - Multi-Function Switch (Flash-to-pass) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1881 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1882 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1883 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1884 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Brake Pressure Switch - Brake Pedal Position Sensor - Multi-Function Switch (Hazards) - Rear Anti-Lock Brakes System Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1885 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1886 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1887 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: - Transmission Range Sensor - Auxiliary Battery Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1888 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1889 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Blend Door Actuator - Selector Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1890 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1891 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: - Instrument Cluster (Air Bag and Charge Indicator) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1892 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1893 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1894 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1895 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Power Seats Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1896 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - Air Bag Diagnostic Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1897 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1898 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: - Overdrive Cancel Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1899 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1900 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: - Power Windows Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1901 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1902 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: - Memory Power Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1903 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: - Cigar Lighter - Data Link Connector Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1904 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1905 Power Distribution Fuse 24 Fuse 24 - protects the following circuits: - Illuminated Entry Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1906 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1907 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: - Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1908 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1909 Power Distribution Fuse 28 Fuse 28 - protects the following circuits: - Power Plug Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1910 Power Distribution Fuse 34 Fuse 34 - protects the following circuits: - Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1911 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1912 Power Distribution Fuse 36 Fuse 36 - protects the following circuits: - Cluster - Radio - Steering Column Assembly Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1913 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1914 Power Distribution Fuse 38 Fuse 38 - protects the following circuits: - Air Bag Diagnostic Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1915 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1916 Power Distribution Fuse 40 Fuse 40 - protects the following circuits: - Modified Vehicle Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1917 Power Distribution Fuse 41 Fuse 40 - protects the following circuits: - Modified Vehicle Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1918 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions Fusible Link: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1923 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1924 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1925 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1926 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1927 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1928 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1929 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1930 Fusible Link: Electrical Diagrams Fuse Link A Fuse Link A - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Power Distribution Fuse Link B Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1931 Fuse Link B - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Power Distribution Fuse Link C Fuse Link C - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1932 Power Distribution Fuse Link D Fuse Link D - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1933 Power Distribution Fuse Link E Fuse Link E - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1934 Power Distribution Fuse Link F Fuse Link F - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1935 Power Distribution Fuse Link G Fuse Link G - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1936 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions CAUTION: - Damage to the suspension or steering linkage system components may occur when positioning the hoist adapters. The front adapter pads should be positioned carefully to ensure maximum contact under the center of the lower suspension arms or spring supports as near the wheels as practical. The rear suspension hoist adapters (forks) should be placed under the spring mounting pads or the rear axle housing tubes, but the adapters must not interfere with the shock absorber mounting brackets or the stabilizer bar mounting brackets. - When raising a vehicle on a twin post hoist, care should be taken to position the vehicle so that the hoisting adapters (forks) do not damage the axle housing cover or contact the rear stabilizer bar or brackets. - For proper wrecker towing procedures, refer to the vehicle Owner Guide. Improper towing of a vehicle can result in transmission damage. Always follow the outlined towing procedures. Refer to the hoist manufacturer's operating manual for proper lifting instructions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles Vehicle Lifting: Service and Repair Cutaway and Cargo Vehicles Frame - Left Front Frame - Right Front Frame - Left Rear Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles > Page 1943 Vehicle Lifting: Service and Repair Drive-On Hoist To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first checking for possible interference between the upright flanges of the hoist rails and the underbody. Should there be interference, the hoist flanges should be modified as necessary and the approach ramps built up to provide the necessary clearance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles > Page 1944 Vehicle Lifting: Service and Repair Frame Contact Hoist Adapters may be necessary to clear any vehicle components (front and rear) to lift the vehicle safely. This will provide enough clearance to prevent damaging the lower body. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles > Page 1945 Vehicle Lifting: Service and Repair Lifting Precautions CAUTION: - Damage to the suspension or steering linkage system components may occur when positioning the hoist adapters. The front adapter pads should be positioned carefully to ensure maximum contact under the center of the lower suspension arms or spring supports as near the wheels as practical. The rear suspension hoist adapters (forks) should be placed under the spring mounting pads or the rear axle housing tubes, but the adapters must not interfere with the shock absorber mounting brackets or the stabilizer bar mounting brackets. - When raising a vehicle on a twin post hoist, care should be taken to position the vehicle so that the hoisting adapters (forks) do not damage the axle housing cover or contact the rear stabilizer bar or brackets. - For proper wrecker towing procedures, refer to the vehicle Owner Guide. Improper towing of a vehicle can result in transmission damage. Always follow the outlined towing procedures. Refer to the hoist manufacturer's operating manual for proper lifting instructions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles > Page 1946 Vehicle Lifting: Service and Repair Cutaway and Cargo Vehicles Frame - Left Front Frame - Right Front Frame - Left Rear Drive-On Hoist To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first checking for possible interference between the upright flanges of the hoist rails and the underbody. Should there be interference, the hoist flanges should be modified as necessary and the approach ramps built up to provide the necessary clearance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles > Page 1947 Frame Contact Hoist Adapters may be necessary to clear any vehicle components (front and rear) to lift the vehicle safely. This will provide enough clearance to prevent damaging the lower body. Lifting Precautions CAUTION: - Damage to the suspension or steering linkage system components may occur when positioning the hoist adapters. The front adapter pads should be positioned carefully to ensure maximum contact under the center of the lower suspension arms or spring supports as near the wheels as practical. The rear suspension hoist adapters (forks) should be placed under the spring mounting pads or the rear axle housing tubes, but the adapters must not interfere with the shock absorber mounting brackets or the stabilizer bar mounting brackets. - When raising a vehicle on a twin post hoist, care should be taken to position the vehicle so that the hoisting adapters (forks) do not damage the axle housing cover or contact the rear stabilizer bar or brackets. - For proper wrecker towing procedures, refer to the vehicle Owner Guide. Improper towing of a vehicle can result in transmission damage. Always follow the outlined towing procedures. Refer to the hoist manufacturer's operating manual for proper lifting instructions. Single Post Hoist Adapters may be necessary to clear any vehicle components (front and rear) to lift the vehicle safely. This will provide enough clearance to prevent damaging the lower body. Twin Post Hoist Damage to the suspension or steering linkage system components may occur when positioning the hoist adapters. The front adapter pads should be positioned carefully to ensure maximum contact under the center of the lower suspension arms or spring supports as near the wheels as practical. The rear suspension hoist adapters (forks) should be placed under the spring mounting pads or the rear axle housing tubes, but the adapters must not interfere with the shock absorber mounting brackets or the stabilizer bar mounting brackets. CAUTION: When raising a vehicle on a twin-post hoist, care should be taken to position the vehicle so that the hoisting adapters (forks) do not damage the axle housing cover or contact the rear stabilizer bar or brackets. Adapters may be necessary to clear any vehicle components (front and rear) to lift the vehicle safely. This will provide enough clearance to prevent damaging the lower body. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1952 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1953 Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1954 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1955 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1956 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1957 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1958 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1959 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1960 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1961 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1962 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1963 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1964 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1965 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1966 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1967 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1968 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1969 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1970 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1971 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1972 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1973 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1974 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1975 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1976 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1977 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1978 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1979 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1980 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1981 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1982 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1983 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1984 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1985 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1986 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1987 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1988 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1989 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1990 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1991 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1992 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1993 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1994 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1995 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1996 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1997 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1998 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1999 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2001 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2002 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2003 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2004 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2005 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2006 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2007 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2008 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2009 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2010 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2011 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2012 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2013 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2014 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2015 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2016 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2017 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2018 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2019 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2020 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2021 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2022 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2023 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2024 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2025 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2026 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2027 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2028 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2029 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2030 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2031 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2032 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2033 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2034 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2035 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2036 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2037 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2038 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2039 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2040 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2041 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2042 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2043 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2044 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2045 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2046 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2047 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2048 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 2049 Tires: Specifications Max. Radial Runout Aluminum ............................................................................................................................................. ..................................... 1.27 mm (0.050 inch) Steel ........................................................................... ................................................................................................................ 1.27 mm (0.050 inch) Max. Lateral Runout Aluminum ............................................................................................................................................. ..................................... 1.27 mm (0.050 inch) Steel ........................................................................... ................................................................................................................ 1.27 mm (0.050 inch) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service Precautions > Customer Safety Information Tires: Customer Safety Information WARNING: - THE TIRE AND WHEEL MUST ALWAYS BE PROPERLY MATCHED. IT IS VERY IMPORTANT TO DETERMINE THE SIZE OF EACH COMPONENT BEFORE ANY ASSEMBLY OPERATIONS COMMENCE. FAILURE TO ADHERE TO THESE INSTRUCTIONS CAN RESULT IN AN EXPLOSIVE SEPARATION AND CAUSE SERIOUS BODILY INJURY OR DEATH. - AFTERMARKET WHEEL ASSEMBLIES MAY NOT BE COMPATIBLE WITH THE VEHICLE. USE OF INCOMPATIBLE WHEEL ASSEMBLIES CAN RESULT IN EQUIPMENT FAILURE AND POSSIBLE INJURY. USE ONLY APPROVED WHEEL ASSEMBLIES. - USE ONLY WHEELS AND LUG NUTS THAT HAVE BEEN DESIGNED FOR CURRENT MODEL YEAR FORD TRUCKS AFTERMARKET WHEELS OR LUG NUTS MAY NOT FIT OR FUNCTION PROPERLY, AND CAN CAUSE PERSONAL INJURY OR DAMAGE THE VEHICLE. - DO NOT MIX DIFFERENT TYPES OF TIRES, SUCH AS RADIAL, BIAS, OR BIAS-BELTED, ON THE SAME VEHICLE EXCEPT IN EMERGENCIES. VEHICLE HANDLING CAN BE SERIOUSLY AFFECTED AND CAN RESULT IN LOSS OF CONTROL. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service Precautions > Customer Safety Information > Page 2052 Tires: Technician Safety Information WARNING: - NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, FOR EXAMPLE, WHEN CHANGING A TIRE. THE WHEEL(S) RESTING ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. - THE TIRE AND WHEEL MUST ALWAYS BE PROPERLY MATCHED. IT IS VERY IMPORTANT TO DETERMINE THE SIZE OF EACH COMPONENT BEFORE ANY ASSEMBLY OPERATIONS COMMENCE. FAILURE TO ADHERE TO THESE INSTRUCTIONS CAN RESULT IN AN EXPLOSIVE SEPARATION AND CAUSE SERIOUS BODILY INJURY OR DEATH. - AFTERMARKET AEROSOL TIRE SEALANTS ARE EXTREMELY FLAMMABLE. ALWAYS QUESTION THE CUSTOMER TO MAKE SURE THESE PRODUCTS HAVE NOT BEEN USED. - AFTERMARKET WHEEL ASSEMBLIES MAY NOT BE COMPATIBLE WITH THE VEHICLE. USE OF INCOMPATIBLE WHEEL ASSEMBLIES CAN RESULT IN EQUIPMENT FAILURE AND POSSIBLE INJURY. USE ONLY APPROVED WHEEL ASSEMBLIES. - USE ONLY WHEELS AND LUG NUTS THAT HAVE BEEN DESIGNED FOR CURRENT MODEL YEAR FORD TRUCKS AFTERMARKET WHEELS OR LUG NUTS MAY NOT FIT OR FUNCTION PROPERLY, AND CAN CAUSE PERSONAL INJURY OR DAMAGE THE VEHICLE. - ALWAYS WEAR SAFETY GOGGLES OR A FACE SHIELD WHEN PERFORMING ANY WORK WITH TIRE AND WHEEL ASSEMBLIES. - DO NOT MIX DIFFERENT TYPES OF TIRES, SUCH AS RADIAL, BIAS, OR BIAS-BELTED, ON THE SAME VEHICLE EXCEPT IN EMERGENCIES. VEHICLE HANDLING CAN BE SERIOUSLY AFFECTED AND CAN RESULT IN LOSS OF CONTROL. - DO NOT BALANCE THE WHEELS AND TIRES WHILE THEY ARE MOUNTED ON THE VEHICLE. POSSIBLE TIRE DISINTEGRATION OR DIFFERENTIAL FAILURE COULD RESULT, CAUSING PERSONAL INJURY AND EXTENSIVE COMPONENT DAMAGE. USE OFF-VEHICLE WHEEL AND TIRE BALANCER ONLY. CAUTION: Reduce the air pressure as much as possible by pushing the valve core plunger in prior to removing the valve core. Avoid working in a position in which the face or body is directly over a tire in which there is pressure. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service Precautions > Customer Safety Information > Page 2053 Tires: Vehicle Damage Warnings WARNING: - NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, FOR EXAMPLE, WHEN CHANGING A TIRE. THE WHEEL(S) RESTING ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. - THE TIRE AND WHEEL MUST ALWAYS BE PROPERLY MATCHED. IT IS VERY IMPORTANT TO DETERMINE THE SIZE OF EACH COMPONENT BEFORE ANY ASSEMBLY OPERATIONS COMMENCE. FAILURE TO ADHERE TO THESE INSTRUCTIONS CAN RESULT IN AN EXPLOSIVE SEPARATION AND CAUSE SERIOUS BODILY INJURY OR DEATH. - AFTERMARKET WHEEL ASSEMBLIES MAY NOT BE COMPATIBLE WITH THE VEHICLE. USE OF INCOMPATIBLE WHEEL ASSEMBLIES CAN RESULT IN EQUIPMENT FAILURE AND POSSIBLE INJURY. USE ONLY APPROVED WHEEL ASSEMBLIES. - USE ONLY WHEELS AND LUG NUTS THAT HAVE BEEN DESIGNED FOR CURRENT MODEL YEAR FORD TRUCKS AFTERMARKET WHEELS OR LUG NUTS MAY NOT FIT OR FUNCTION PROPERLY, AND CAN CAUSE PERSONAL INJURY OR DAMAGE THE VEHICLE. - DO NOT MIX DIFFERENT TYPES OF TIRES, SUCH AS RADIAL, BIAS, OR BIAS-BELTED, ON THE SAME VEHICLE EXCEPT IN EMERGENCIES. VEHICLE HANDLING CAN BE SERIOUSLY AFFECTED AND CAN RESULT IN LOSS OF CONTROL. - DO NOT BALANCE THE WHEELS AND TIRES WHILE THEY ARE MOUNTED ON THE VEHICLE. POSSIBLE TIRE DISINTEGRATION OR DIFFERENTIAL FAILURE COULD RESULT, CAUSING PERSONAL INJURY AND EXTENSIVE COMPONENT DAMAGE. USE OFF-VEHICLE WHEEL AND TIRE BALANCER ONLY. CAUTION: Do not clean aluminum wheels with steel wool. abrasive-type cleaners or strong detergents. Use Custom Bright Metal Cleaner 8A-19522-A or equivalent meeting Ford specifications ESR-M5B194-B. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Tires: Initial Inspection and Diagnostic Overview Verify the customer concern by performing a road test on a smooth road. To maximize tire performances inspect for signs of improper inflation and uneven wear, which may indicate a need for balancing, rotation, or front suspension alignment. Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increases tire wear. Replacement tires must follow the recommended: - tire sizes. - speed rating. - load range. - radial construction type. Use of any other tire size or type can seriously affect: - ride. - handling. - speedometer/odometer calibration. - vehicle ground clearance. - tire clearance between the body and chassis. - wheel bearing life. - brake cooling. Wheels need to be replaced when: - bent. - cracked. - dented. - heavily rusted. - leaking. - they have elongated wheel hub bolt holes. - they have excessive lateral or radial runout. Wheel and tire assemblies are attached by five noncentering lug nuts. It is mandatory to use only the tire sizes recommended on the tire chart attached to the vehicle. Larger or smaller tires can damage the vehicle, affect durability, and require changing the speedometer calibration Make sure wheel size and offsets match those recommended for the tire in use. 1. Inspect for signs of uneven wear that may indicate a need for balancing, rotation front suspension alignments damaged tie rod, or steering components. 2. Check tires for: - cuts. - stone bruises. - abrasions - blisters. - embedded objects. 3. Tread wear indicators are molded into the bottom of the tread grooves. Replace the tire when the indicator bands become visible. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2056 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2057 Tires: Component Tests and General Diagnostics DESCRIPTION Excessive radial and lateral runout of a wheel and tire assembly can cause roughness, vibration, wheel tramp, tire wear, and steering wheel tremor. Before checking runout, and to avoid false readings caused by temporary flat spots in the tires, check runout only after the vehicle has been driven far enough to warm the tires. Measure the extent of the runout with Rotunda Radial Runout Gauge. All measurements are made on the vehicle with the tires inflated to recommended inflation pressures and with the front wheel bearings adjusted to specifications. TIRE RUNOUT Measure radial and lateral tire runout at the positions shown. Runout should not exceed 1.27 mm (0.050 inch). WHEEL RUNOUT Measure radial and lateral wheel runout at the positions shown. Runout should not exceed 1.12 mm (0.044 inch) in either position. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-24-8 > Dec > 05 > Wheels/Tires - Vibration Above 45 MPH Wheels: Customer Interest Wheels/Tires - Vibration Above 45 MPH TSB 05-24-8 12/12/05 VIBRATION/HARSHNESS ABOVE 45 MPH (72 KM/H) AFTER TIRE BALANCE FORD: 1997-2006 E-Series ISSUE Some E-Series vehicles equipped with Single Rear Wheel, 16-inch steel wheels with eight (8) lug bolt holes may experience vehicle vibration at 45 MPH (72 Km/h) or higher after balancing wheel/tire assemblies. ACTION Balancing E-Series steel wheels, both the rear lip of the wheel center opening and the curb side of the lug bolt holes must be used simultaneously to correctly align the assembly on the balancing machine. Balancing machines that include balance, rim runout, and road force variation measurement capabilities like Hunter Models 9100, 9600 or 9700 with the following Service Procedure. SERVICE PROCEDURE NOTE BALANCING E-SERIES STEEL WHEELS, BOTH THE REAR LIP OF THE WHEEL CENTER OPENING AND THE CURB SIDE OF THE LUG BOLT HOLES MUST BE USED SIMULTANEOUSLY TO CORRECTLY ALIGN THE ASSEMBLY ON THE BALANCING MACHINE. Correct positioning of the tire and wheel assemblies on the balancing machine spindle. 1. Install the spacer ring. The spacer ring allows for the wheel offset and prevents contact of the tire with the balancer machine. 2. Install the low-taper cone. Align the cone so that the 110 tapered face engages the wheel center opening. 3. Place the wheel assembly with the curb side of the wheel facing away from the cone. The cone must engage the back of the wheel center opening. 4. Install the flange. Either an adjustable or a fixed flange is suitable. Flange fingers should be adjusted to contact every other lug bolt hole (5 fingers for the 8-bolt wheel) of the bolt circle pattern. 5. Secure the assembly using the appropriate nut on the balancer spindle. NOTE THIS MACHINE SET-UP REPLICATES THE IN-VEHICLE WHEEL POSITION WHERE LUG BOLTS CLAMP THE BACK OF THE WHEEL AGAINST THE AXLE FLANGE. NOTE USE OF A BALANCER MOUNTING CONE ON THE CURB SIDE OF THE WHEEL WILL NOT PERMIT CORRECT WHEEL POSITIONING ON THE BALANCER. THE WHEEL CENTER OPENING IS FORMED FROM THE BACK, AND THE METAL EDGE ON THE CURB SIDE OF THE CENTER OPENING IS NOT DESIGNED TO ACCURATELY POSITION THE WHEEL. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE ALBAL D9 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-24-8 > Dec > 05 > Wheels/Tires - Vibration Above 45 MPH Wheels: All Technical Service Bulletins Wheels/Tires - Vibration Above 45 MPH TSB 05-24-8 12/12/05 VIBRATION/HARSHNESS ABOVE 45 MPH (72 KM/H) AFTER TIRE BALANCE FORD: 1997-2006 E-Series ISSUE Some E-Series vehicles equipped with Single Rear Wheel, 16-inch steel wheels with eight (8) lug bolt holes may experience vehicle vibration at 45 MPH (72 Km/h) or higher after balancing wheel/tire assemblies. ACTION Balancing E-Series steel wheels, both the rear lip of the wheel center opening and the curb side of the lug bolt holes must be used simultaneously to correctly align the assembly on the balancing machine. Balancing machines that include balance, rim runout, and road force variation measurement capabilities like Hunter Models 9100, 9600 or 9700 with the following Service Procedure. SERVICE PROCEDURE NOTE BALANCING E-SERIES STEEL WHEELS, BOTH THE REAR LIP OF THE WHEEL CENTER OPENING AND THE CURB SIDE OF THE LUG BOLT HOLES MUST BE USED SIMULTANEOUSLY TO CORRECTLY ALIGN THE ASSEMBLY ON THE BALANCING MACHINE. Correct positioning of the tire and wheel assemblies on the balancing machine spindle. 1. Install the spacer ring. The spacer ring allows for the wheel offset and prevents contact of the tire with the balancer machine. 2. Install the low-taper cone. Align the cone so that the 110 tapered face engages the wheel center opening. 3. Place the wheel assembly with the curb side of the wheel facing away from the cone. The cone must engage the back of the wheel center opening. 4. Install the flange. Either an adjustable or a fixed flange is suitable. Flange fingers should be adjusted to contact every other lug bolt hole (5 fingers for the 8-bolt wheel) of the bolt circle pattern. 5. Secure the assembly using the appropriate nut on the balancer spindle. NOTE THIS MACHINE SET-UP REPLICATES THE IN-VEHICLE WHEEL POSITION WHERE LUG BOLTS CLAMP THE BACK OF THE WHEEL AGAINST THE AXLE FLANGE. NOTE USE OF A BALANCER MOUNTING CONE ON THE CURB SIDE OF THE WHEEL WILL NOT PERMIT CORRECT WHEEL POSITIONING ON THE BALANCER. THE WHEEL CENTER OPENING IS FORMED FROM THE BACK, AND THE METAL EDGE ON THE CURB SIDE OF THE CENTER OPENING IS NOT DESIGNED TO ACCURATELY POSITION THE WHEEL. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE ALBAL D9 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 2075 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2080 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2081 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2082 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2083 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2084 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2085 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2086 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2087 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2088 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2089 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2090 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2091 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2092 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2093 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2094 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2095 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2096 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2097 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2098 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2099 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2100 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2101 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2102 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2103 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2104 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2105 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2106 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2107 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2108 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2109 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2110 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2111 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2112 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2113 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2114 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2115 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2116 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2117 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2118 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2119 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2120 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2121 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2122 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2123 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2124 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2125 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2126 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2127 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2128 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2129 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2130 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2131 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2132 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2133 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2134 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2135 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2136 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2137 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2138 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2139 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2140 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2141 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2142 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2143 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2144 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2145 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2146 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2147 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2148 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2149 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2150 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2151 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2152 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2153 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2154 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2155 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2156 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2157 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2158 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2159 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2160 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2161 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2162 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2163 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2164 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2165 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2166 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2167 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2168 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2169 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2170 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2171 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2172 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2173 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2174 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 2180 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2185 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2186 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2187 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2188 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2189 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2190 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2191 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2192 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2193 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2194 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2195 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2196 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2197 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2198 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2199 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2200 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2201 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2202 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2203 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2204 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2205 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2206 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2207 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2208 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2209 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2210 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2211 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2212 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2213 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2214 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2215 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2216 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2217 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2218 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2219 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2220 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2221 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2222 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2223 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2224 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2225 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2226 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2227 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2228 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2229 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2230 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2231 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2232 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2233 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2234 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2235 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2236 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2237 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2238 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2239 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2240 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2241 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2242 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2243 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2244 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2245 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2246 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2247 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2248 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2249 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2250 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2251 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2252 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2253 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2254 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2255 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2256 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2257 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2258 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2259 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2260 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2261 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2262 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2263 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2264 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2265 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2266 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2267 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2268 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2269 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2270 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2271 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2272 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2273 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2274 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2275 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2276 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2277 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2278 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2279 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service Precautions > Customer Safety Information Wheels: Customer Safety Information WARNING: - THE TIRE AND WHEEL MUST ALWAYS BE PROPERLY MATCHED. IT IS VERY IMPORTANT TO DETERMINE THE SIZE OF EACH COMPONENT BEFORE ANY ASSEMBLY OPERATIONS COMMENCE. FAILURE TO ADHERE TO THESE INSTRUCTIONS CAN RESULT IN AN EXPLOSIVE SEPARATION AND CAUSE SERIOUS BODILY INJURY OR DEATH. - AFTERMARKET WHEEL ASSEMBLIES MAY NOT BE COMPATIBLE WITH THE VEHICLE. USE OF INCOMPATIBLE WHEEL ASSEMBLIES CAN RESULT IN EQUIPMENT FAILURE AND POSSIBLE INJURY. USE ONLY APPROVED WHEEL ASSEMBLIES. - USE ONLY WHEELS AND LUG NUTS THAT HAVE BEEN DESIGNED FOR CURRENT MODEL YEAR FORD TRUCKS AFTERMARKET WHEELS OR LUG NUTS MAY NOT FIT OR FUNCTION PROPERLY, AND CAN CAUSE PERSONAL INJURY OR DAMAGE THE VEHICLE. - DO NOT MIX DIFFERENT TYPES OF TIRES, SUCH AS RADIAL, BIAS, OR BIAS-BELTED, ON THE SAME VEHICLE EXCEPT IN EMERGENCIES. VEHICLE HANDLING CAN BE SERIOUSLY AFFECTED AND CAN RESULT IN LOSS OF CONTROL. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service Precautions > Customer Safety Information > Page 2282 Wheels: Technician Safety Information WARNING: - NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, FOR EXAMPLE, WHEN CHANGING A TIRE. THE WHEEL(S) RESTING ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. - THE TIRE AND WHEEL MUST ALWAYS BE PROPERLY MATCHED. IT IS VERY IMPORTANT TO DETERMINE THE SIZE OF EACH COMPONENT BEFORE ANY ASSEMBLY OPERATIONS COMMENCE. FAILURE TO ADHERE TO THESE INSTRUCTIONS CAN RESULT IN AN EXPLOSIVE SEPARATION AND CAUSE SERIOUS BODILY INJURY OR DEATH. - AFTERMARKET AEROSOL TIRE SEALANTS ARE EXTREMELY FLAMMABLE. ALWAYS QUESTION THE CUSTOMER TO MAKE SURE THESE PRODUCTS HAVE NOT BEEN USED. - AFTERMARKET WHEEL ASSEMBLIES MAY NOT BE COMPATIBLE WITH THE VEHICLE. USE OF INCOMPATIBLE WHEEL ASSEMBLIES CAN RESULT IN EQUIPMENT FAILURE AND POSSIBLE INJURY. USE ONLY APPROVED WHEEL ASSEMBLIES. - USE ONLY WHEELS AND LUG NUTS THAT HAVE BEEN DESIGNED FOR CURRENT MODEL YEAR FORD TRUCKS AFTERMARKET WHEELS OR LUG NUTS MAY NOT FIT OR FUNCTION PROPERLY, AND CAN CAUSE PERSONAL INJURY OR DAMAGE THE VEHICLE. - ALWAYS WEAR SAFETY GOGGLES OR A FACE SHIELD WHEN PERFORMING ANY WORK WITH TIRE AND WHEEL ASSEMBLIES. - DO NOT MIX DIFFERENT TYPES OF TIRES, SUCH AS RADIAL, BIAS, OR BIAS-BELTED, ON THE SAME VEHICLE EXCEPT IN EMERGENCIES. VEHICLE HANDLING CAN BE SERIOUSLY AFFECTED AND CAN RESULT IN LOSS OF CONTROL. - DO NOT BALANCE THE WHEELS AND TIRES WHILE THEY ARE MOUNTED ON THE VEHICLE. POSSIBLE TIRE DISINTEGRATION OR DIFFERENTIAL FAILURE COULD RESULT, CAUSING PERSONAL INJURY AND EXTENSIVE COMPONENT DAMAGE. USE OFF-VEHICLE WHEEL AND TIRE BALANCER ONLY. CAUTION: Reduce the air pressure as much as possible by pushing the valve core plunger in prior to removing the valve core. Avoid working in a position in which the face or body is directly over a tire in which there is pressure. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service Precautions > Customer Safety Information > Page 2283 Wheels: Vehicle Damage Warnings WARNING: - NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, FOR EXAMPLE, WHEN CHANGING A TIRE. THE WHEEL(S) RESTING ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. - THE TIRE AND WHEEL MUST ALWAYS BE PROPERLY MATCHED. IT IS VERY IMPORTANT TO DETERMINE THE SIZE OF EACH COMPONENT BEFORE ANY ASSEMBLY OPERATIONS COMMENCE. FAILURE TO ADHERE TO THESE INSTRUCTIONS CAN RESULT IN AN EXPLOSIVE SEPARATION AND CAUSE SERIOUS BODILY INJURY OR DEATH. - AFTERMARKET WHEEL ASSEMBLIES MAY NOT BE COMPATIBLE WITH THE VEHICLE. USE OF INCOMPATIBLE WHEEL ASSEMBLIES CAN RESULT IN EQUIPMENT FAILURE AND POSSIBLE INJURY. USE ONLY APPROVED WHEEL ASSEMBLIES. - USE ONLY WHEELS AND LUG NUTS THAT HAVE BEEN DESIGNED FOR CURRENT MODEL YEAR FORD TRUCKS AFTERMARKET WHEELS OR LUG NUTS MAY NOT FIT OR FUNCTION PROPERLY, AND CAN CAUSE PERSONAL INJURY OR DAMAGE THE VEHICLE. - DO NOT MIX DIFFERENT TYPES OF TIRES, SUCH AS RADIAL, BIAS, OR BIAS-BELTED, ON THE SAME VEHICLE EXCEPT IN EMERGENCIES. VEHICLE HANDLING CAN BE SERIOUSLY AFFECTED AND CAN RESULT IN LOSS OF CONTROL. - DO NOT BALANCE THE WHEELS AND TIRES WHILE THEY ARE MOUNTED ON THE VEHICLE. POSSIBLE TIRE DISINTEGRATION OR DIFFERENTIAL FAILURE COULD RESULT, CAUSING PERSONAL INJURY AND EXTENSIVE COMPONENT DAMAGE. USE OFF-VEHICLE WHEEL AND TIRE BALANCER ONLY. CAUTION: Do not clean aluminum wheels with steel wool. abrasive-type cleaners or strong detergents. Use Custom Bright Metal Cleaner 8A-19522-A or equivalent meeting Ford specifications ESR-M5B194-B. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Wheels: Initial Inspection and Diagnostic Overview Verify the customer concern by performing a road test on a smooth road. To maximize tire performances inspect for signs of improper inflation and uneven wear, which may indicate a need for balancing, rotation, or front suspension alignment. Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increases tire wear. Replacement tires must follow the recommended: - tire sizes. - speed rating. - load range. - radial construction type. Use of any other tire size or type can seriously affect: - ride. - handling. - speedometer/odometer calibration. - vehicle ground clearance. - tire clearance between the body and chassis. - wheel bearing life. - brake cooling. Wheels need to be replaced when: - bent. - cracked. - dented. - heavily rusted. - leaking. - they have elongated wheel hub bolt holes. - they have excessive lateral or radial runout. Wheel and tire assemblies are attached by five noncenter1ng lug nuts. It is mandatory to use only the tire sizes recommended on the tire chart attached to the vehicle. Larger or smaller tires can damage the vehicle, affect durability, and require changing the speedometer calibration Make sure wheel size and offsets match those recommended for the tire in use. 1. Inspect for signs of uneven wear that may indicate a need for balancing, rotation front suspension alignments damaged tie rod, or steering components. 2. Check tires for: - cuts. - stone bruises. - abrasions - blisters. - embedded objects. 3. Tread wear indicators are molded into the bottom of the tread grooves. Replace the tire when the indicator bands become visible. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2286 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2287 Wheels: Component Tests and General Diagnostics DESCRIPTION Excessive radial and lateral runout of a wheel and tire assembly can cause roughness, vibration, wheel tramp, tire wear, and steering wheel tremor. Before checking runout, and to avoid false readings caused by temporary flat spots in the tires, check runout only after the vehicle has been driven far enough to warm the tires. Measure the extent of the runout with Rotunda Radial Runout Gauge. All measurements are made on the vehicle with the tires inflated to recommended inflation pressures and with the front wheel bearings adjusted to specifications. TIRE RUNOUT Measure radial and lateral tire runout at the positions shown. Runout should not exceed 1.27 mm (0.050 inch). WHEEL RUNOUT Measure radial and lateral wheel runout at the positions shown. Runout should not exceed 1.12 mm (0.044 inch) in either position. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Dual Rear Wheels Wheels: Service and Repair Dual Rear Wheels REMOVAL WARNING: - AFTERMARKET WHEEL ASSEMBLIES MAY NOT BE COMPATIBLE WITH THE VEHICLE. USE OF INCOMPATIBLE WHEEL ASSEMBLIES CAN RESULT IN EQUIPMENT FAILURE AND POSSIBLE INJURY. USE ONLY APPROVED WHEEL ASSEMBLIES. - USE ONLY INTEGRAL TWO-PIECE SWIVELING LUG NUTS ON VEHICLES EQUIPPED WITH DUAL REAR WHEELS. DO NOT ATTEMPT TO USE CONE-SHAPED ONE-PIECE LUG NUTS ON THESE VEHICLES. IF USED, CONE-SHAPED ONE-PIECE LUG NUTS CAN COME LOOSE IN VEHICLE OPERATION. DO NOT ATTEMPT TO USE PAST MODEL WHEELS, WHICH HAVE CONE-SHAPED WHEEL HUB BOLT NUT SEATS, ON THIS VEHICLE. DO NOT ATTEMPT TO USE PRESENT DESIGN WHEELS AND LUG NUTS ON PAST MODEL WHEEL HUBS. ATTEMPTED USE OF INTERMIXED WHEELS CAN LEAD TO DAMAGE TO THE WHEEL MOUNTING SYSTEM AND COULD RESULT IN WHEELS COMING LOOSE. 1. Remove the wheel cover if so equipped. 2. With the weight of the vehicle still on the tires, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. NOTE: Do not remove the lug nuts at this time. 3. Raise the vehicle until the wheel and tire assembly clears the floor. 4. Remove the lug nuts. Remove the inner and outer wheel and tire assemblies from the rear hub. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Dual Rear Wheels > Page 2290 INSTALLATION 1. Mount the inner wheel on the rear hub with the wheel dish facing inboard. WARNING: WHEN A WHEEL IS INSTALLED, ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEELS OR THE SURFACES OF THE REAR HUB THAT CONTACT THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUT TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, RESULTING IN LOSS OF CONTROL. 2. Align the wheel with the small indexing hole, located in the wheel between the wheel hub bolt holes, with the alignment pin in the hole in the rear hub. 3. Make sure the wheel is flush with the rear wheel hub mounting surface so there is no gap between the rear hub and the wheel. 4. Install the outer rear wheel flush against the inner wheel with the hub alignment locating pin protruding through the wheel index hole 5. Install the lug nuts and tighten until snug. 6. With the lug nuts loosely installed, turn the wheel until one lug nut is at the top of the wheel hub bolt circle. Tighten the swiveling lug nut until snug. In a crisscross-type pattern, tighten the remaining lug nuts until snug to minimize runout. 7. Lower the vehicle. 8. Tighten the lug nuts to specification. 9. Install the wheel cover, if so equipped. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Dual Rear Wheels > Page 2291 Wheels: Service and Repair Single Wheel REMOVAL 1. Remove the wheel cover, if so equipped. 2. With the weight of the vehicle still on the tires, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. NOTE: Do not remove the lug nuts at this time. 3. Raise the vehicle until the wheel and tire assembly clears the floor. 4. Remove the lug nuts. 5. Remove the wheel and tire assembly. INSTALLATION 1. Position the wheel and tire assembly on the vehicle. WARNING: WHEN A WHEEL IS INSTALLED, ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE FRONT DISC BRAKE HUB AND ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUTS TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, RESULTING IN LOSS OF CONTROL. 2. Install the lug nuts loosely. Make sure the cone ends of the lug nut face inward. 3. Turn the wheel until one lug nut is at the top of the wheel hub bolt circle. Tighten the lug nut until snug. In a crisscross-type pattern tighten the remaining lug nuts until snug to minimize runout. 4. Lower the vehicle. 5. Tighten the lug nuts to specification. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high rotor runout, which will speed up the development of brake roughness, shudder and vibration. 6. Install the wheel cover, if so equipped. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2296 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2297 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2298 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2299 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2300 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2301 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2302 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2303 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2304 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2305 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2306 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2307 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2308 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2309 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2310 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2311 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2312 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2313 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2314 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2315 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2316 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2317 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2318 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2319 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2320 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2321 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2322 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2323 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2324 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2325 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2326 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2327 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2328 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2329 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2330 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2331 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2332 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2333 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2334 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2335 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2336 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2337 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2338 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2339 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2340 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2341 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2342 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2343 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2344 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2345 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2346 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2347 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2348 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2349 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2351 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2352 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2353 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2354 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2355 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2356 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2357 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2358 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2359 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2360 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2361 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2362 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2363 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2364 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2365 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2366 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2367 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2368 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2369 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2370 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2371 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2372 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2373 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2374 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2375 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2376 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2377 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2378 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2379 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2380 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2381 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2382 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2383 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2384 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2385 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2386 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2387 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2388 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2389 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2390 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Front Wheel Bearing: Specifications Front Lubricate the front wheel bearings. Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Front > Page 2393 Wheel Bearing: Specifications Rear Dana Semi-Floating Axle Lubricate the cavity between the lips of the axle shaft oil seal and the rear wheel bearing with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Ford Axles Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 2394 Wheel Bearing: Description and Operation Part 1 Of 2 Part 2 Of 2 SINGLE REAR WHEEL, E-350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 2395 DUAL REAR WHEEL, E-350 WHEEL HUBS AND BEARINGS The rear hub is supported or floats on the axle spindle on two opposed tapered roller bearings. The rear hub is retained on the spindle by a ratcheting nut that is tabbed to a slot on the spindle. The brake drum is mounted to the rear hub. A seal is installed inboard of the inner rear wheel bearing to keep the rear axle and wheel bearing lubricant from the brake components. The full-floating rear axles on E-350 vehicles have brake drums mounted outboard of the rear hub, permitting brake drum removal for brake inspection without the need to remove the rear hub. The E-Super Duty full-floating axle has rear disc brakes. The rear disc brake rotor is mounted to the rear hub. The rear wheel bearings are packed with a lithium-base grease, Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B, to provide initial lubrication until axle lubricant flows into the rear hubs and rear wheel bearing inner cone and rollers during vehicle operation. Vehicles equipped with Dual Rear Wheel (DRW) rear axles have the wheels attached to the brake drum on the E-350 vehicles or rear hub on E-Super Duty vehicles. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 2396 Wheel Bearing: Testing and Inspection 1. Raise the vehicle until the tire is off the floor. 2. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, adjust the front wheel bearings. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle Wheel Bearing: Service and Repair Dana Semi-Floating Axle Special Tools Special Tools REMOVAL 1. Remove the axle shaft. 2. Remove and discard the axle shaft oil seal from the axle tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 2399 NOTE: If only the seal needs to be replaced, it can be pried out of the tube bore. Use care to avoid damaging the seal bore. NOTE: The axle shaft oil seal can be removed with the rear wheel bearing as a unit. 3. Remove the rear wheel bearing. 1. Install the Front Hub Remover/Replacer, the Hub Remover Adapters and the Rear Axle Bearing Remover. 2. Pull the rear rear wheel bearing from the axle tube. WARNING: WEAR SAFETY GLASSES WHEN REMOVING THE REAR WHEEL BEARING. 4. Clean and inspect the rear wheel bearing bore. - Wipe the bore with emery cloth to ensure a smooth surface. - Clean out the bore with a standard metal-cleaning solvent. Wipe this area clean, making sure it is free of dirt or any other contaminants. NOTE: The rear wheel bearing bore must be free from nicks and burrs. If the bore has burrs or spalled areas and a new rear wheel bearing is installed, early failure can result. INSTALLATION 1. Coat the rear wheel bearing with differential lubricant for easier assembly and to prevent possible scoring of the tube bore. 2. Using the Front Hub Remover/Replacer, Hub Remover Adapters, Step Plate and the Rear Axle Bearing Replacer, install the rear rear wheel bearing. NOTE: During bearing installation, make sure the rear wheel bearing is not cocked in the bore. NOTE: Install the rear wheel bearing, with identification numbers on the rear wheel bearing facing out. 3. Using the Front Hub Remover/Replacer, the Hub Remover Adapters, the Step Plate and the Rear Axle Seal Replacer, install a new axle shaft oil Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 2400 seal. An alternate method of installing the axle shaft oil seal is with the Rear Axle Seal Replacer and Drive Handle. NOTE: Make sure the oil seal is not cocked in the bore during installation. 4. Lubricate the cavity between the lips of the axle shaft oil seal and the rear wheel bearing with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 5. Install the axle shaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 2401 Wheel Bearing: Service and Repair Ford 8.8 Inch Ring Gear Special Tools REMOVAL 1. Remove the axle shaft. 2. Use Impact Slide Hammer and Rear Axle Bearing Remover to remove the rear axle bearing and inner wheel bearing oil seal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 2402 NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged. INSTALLATION 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use Axle Tube Bearing Replacer with Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-l-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Use Axle Tube Seal Replacer with Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shaft. 9.75 Inch Ring Gear Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 2403 Special Tools REMOVAL 1. Remove the axle shaft. 2. Use the Impact Slide Hammer and the Axle Wheel Bearing Puller to remove the rear wheel bearing and inner wheel bearing oil seal. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged. INSTALLATION 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use the Axle Wheel Bearing Replacer with the Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 2404 4. Use the Axle Seat Replacer with the Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub Nut ............................................................................................................................................... ......................................... 88-102 Nm (65-75 ft. lbs.) (Back off 90 degrees, then retighten) ......................................................................................................................................... 20-27 Nm (15-20 ft. lbs.) Maximum Hub Rotating [1] .................................................................................................................. ............................................... 2.3 Nm (20 inch lbs.) [1] Final adjustment is 0 mm (0 inch) end play. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TORQUE SPECIFICATIONS Lug Nut, 8-Lug Wheel 9/16-18: 170-230 Nm (126-170 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the wheel and tire assembly. 3. Remove the front disc brake hub and rotor assembly. 4. Using a suitable press, remove the lug bolt from the front disc brake hub and rotor assembly. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2414 Wheel Fastener: Service and Repair Rear REMOVAL CAUTION: Never use a hammer to remove the lug bolt. Damage to the axle flange, hub flange, wheel bearing or hub bearing can result. 1. Raise the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. If drum brake, proceed to Step 4. Remove the rear disc brake caliper, rear disc support bracket and rear disc brake rotor if so equipped. Support rear disc brake caliper with safety wire. 4. Remove the rear brake drum. 5. Using C-Frame and Clamp Assembly Tool, press the lug bolt from its seat and discard. INSTALLATION CAUTION: Never use air tools to install lug bolts. The serrations can be stripped from the stud. 1. Insert a new lug bolt in the hole in the axle flange or hub flange, making sure serrations are aligned with those made by the original lug bolt. 2. Seat new lug bolt in axle flange or hub flange. - Place four flatwashers over the outside end of the lug bolt. - Thread a standard lug nut with the flat side against the washers. - Tighten the lug nut until the lug bolt head seats against the back side of the flange. 3. Remove the lug nut and flatwashers. 4. If drum brake, proceed to Step 5. Install the rear disc brake rotor, rear disc support bracket and the rear disc brake caliper, if so equipped. 5. Install the rear brake drum. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2415 6. Install the wheel and tire assembly. 7. Lower the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Page 2416 Special Tool(s) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions CAUTION: - Damage to the suspension or steering linkage system components may occur when positioning the hoist adapters. The front adapter pads should be positioned carefully to ensure maximum contact under the center of the lower suspension arms or spring supports as near the wheels as practical. The rear suspension hoist adapters (forks) should be placed under the spring mounting pads or the rear axle housing tubes, but the adapters must not interfere with the shock absorber mounting brackets or the stabilizer bar mounting brackets. - When raising a vehicle on a twin post hoist, care should be taken to position the vehicle so that the hoisting adapters (forks) do not damage the axle housing cover or contact the rear stabilizer bar or brackets. - For proper wrecker towing procedures, refer to the vehicle Owner Guide. Improper towing of a vehicle can result in transmission damage. Always follow the outlined towing procedures. Refer to the hoist manufacturer's operating manual for proper lifting instructions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles Vehicle Lifting: Service and Repair Cutaway and Cargo Vehicles Frame - Left Front Frame - Right Front Frame - Left Rear Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles > Page 2422 Vehicle Lifting: Service and Repair Drive-On Hoist To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first checking for possible interference between the upright flanges of the hoist rails and the underbody. Should there be interference, the hoist flanges should be modified as necessary and the approach ramps built up to provide the necessary clearance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles > Page 2423 Vehicle Lifting: Service and Repair Frame Contact Hoist Adapters may be necessary to clear any vehicle components (front and rear) to lift the vehicle safely. This will provide enough clearance to prevent damaging the lower body. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles > Page 2424 Vehicle Lifting: Service and Repair Lifting Precautions CAUTION: - Damage to the suspension or steering linkage system components may occur when positioning the hoist adapters. The front adapter pads should be positioned carefully to ensure maximum contact under the center of the lower suspension arms or spring supports as near the wheels as practical. The rear suspension hoist adapters (forks) should be placed under the spring mounting pads or the rear axle housing tubes, but the adapters must not interfere with the shock absorber mounting brackets or the stabilizer bar mounting brackets. - When raising a vehicle on a twin post hoist, care should be taken to position the vehicle so that the hoisting adapters (forks) do not damage the axle housing cover or contact the rear stabilizer bar or brackets. - For proper wrecker towing procedures, refer to the vehicle Owner Guide. Improper towing of a vehicle can result in transmission damage. Always follow the outlined towing procedures. Refer to the hoist manufacturer's operating manual for proper lifting instructions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles > Page 2425 Vehicle Lifting: Service and Repair Cutaway and Cargo Vehicles Frame - Left Front Frame - Right Front Frame - Left Rear Drive-On Hoist To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first checking for possible interference between the upright flanges of the hoist rails and the underbody. Should there be interference, the hoist flanges should be modified as necessary and the approach ramps built up to provide the necessary clearance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles > Page 2426 Frame Contact Hoist Adapters may be necessary to clear any vehicle components (front and rear) to lift the vehicle safely. This will provide enough clearance to prevent damaging the lower body. Lifting Precautions CAUTION: - Damage to the suspension or steering linkage system components may occur when positioning the hoist adapters. The front adapter pads should be positioned carefully to ensure maximum contact under the center of the lower suspension arms or spring supports as near the wheels as practical. The rear suspension hoist adapters (forks) should be placed under the spring mounting pads or the rear axle housing tubes, but the adapters must not interfere with the shock absorber mounting brackets or the stabilizer bar mounting brackets. - When raising a vehicle on a twin post hoist, care should be taken to position the vehicle so that the hoisting adapters (forks) do not damage the axle housing cover or contact the rear stabilizer bar or brackets. - For proper wrecker towing procedures, refer to the vehicle Owner Guide. Improper towing of a vehicle can result in transmission damage. Always follow the outlined towing procedures. Refer to the hoist manufacturer's operating manual for proper lifting instructions. Single Post Hoist Adapters may be necessary to clear any vehicle components (front and rear) to lift the vehicle safely. This will provide enough clearance to prevent damaging the lower body. Twin Post Hoist Damage to the suspension or steering linkage system components may occur when positioning the hoist adapters. The front adapter pads should be positioned carefully to ensure maximum contact under the center of the lower suspension arms or spring supports as near the wheels as practical. The rear suspension hoist adapters (forks) should be placed under the spring mounting pads or the rear axle housing tubes, but the adapters must not interfere with the shock absorber mounting brackets or the stabilizer bar mounting brackets. CAUTION: When raising a vehicle on a twin-post hoist, care should be taken to position the vehicle so that the hoisting adapters (forks) do not damage the axle housing cover or contact the rear stabilizer bar or brackets. Adapters may be necessary to clear any vehicle components (front and rear) to lift the vehicle safely. This will provide enough clearance to prevent damaging the lower body. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Compression Test Compression Check: Testing and Inspection Compression Test 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly 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 five 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. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Compression Test > Page 2434 Compression Check: Testing and Inspection Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating improperly. 3. If two 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 percent of the highest reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Compression Test > Page 2435 Compression Check: Testing and Inspection Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification WSS-M2C153-F on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications TORQUE SPECIFICATIONS Camshaft Bearing Cap Bolts: 8-12 Nm (71-106 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Page 2440 Camshaft Bearing: Testing and Inspection 1. Inspect bearings for the following defects. Possible causes are shown: - cratering-fatigue failure (A) - spot polishing-improper seating (B) - scratching-dirty (C) - base exposed-poor lubrication (D) - both edges worn-journal damaged (E) - one edge worn-journal tapered or bearing not seated (F) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications TORQUE SPECIFICATIONS Camshaft Sprocket Bolts ............................................................................................................................................................ 55-75 Nm (41-55 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Testing and Inspection > Gears Camshaft Gear/Sprocket: Testing and Inspection Gears 1. Inspect the (A) camshaft thrust plate, the (B) cam gear and the (C) crank gear. - Replace as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Testing and Inspection > Gears > Page 2446 Camshaft Gear/Sprocket: Testing and Inspection Sprockets 1. Inspect the (A) timing chain/belt and the (B) sprockets. - Replace as necessary. WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHICLE, DO NOT OPERATE THE ENGINE WITH THE HOOD OPEN UNTIL THE FAN BLADE HAS BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION. NOTE: Specifications show the expected minimum or maximum condition. - If a component fails to meet the specifications, it is necessary to replace or refinish. If the component can be refinished, wear limits are provided as an aid to making a decision. Any component that fails to meet specifications and cannot be refinished must be replaced. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications GENERAL SPECIFICATIONS Lobe Lift Intake ................................................................................................................................................... ..................................................... 6.58077 mm Exhaust ..................................................................... ................................................................................................................................ 6.58551 mm Lobe Lift - Allowable Lift Loss .............................................................................................................. ......................................................................... 0 Valve Lift @ Zero Lash Intake ................................................................................................................................................... ........................................................ 12.00 mm Exhaust ...................................................................... ................................................................................................................................... 12.00 mm Camshaft End Play .............................................................................................................................. ....................................................... 0.25-0.188 mm End Play Service Limit ....................................... ..................................................................................................................................... 0.025-0.188 mm Journal to Bearing Clearance ....................................................................................................... ............................................................ 0.076-0.025 mm Clearance Service Limit Journal Diameters .............................................................................................................................................................. .................. 26.962-26.936 mm Journal Inside Diameter (Cap Assembled) ........................................................................................................................................... 27.012-26.987 mm Camshaft Runout: Full Indicator Measurement on all journals when supported on front and rear journals ................................................................... ................................................................................................ 0.09 mm (5 places) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal Camshaft: Testing and Inspection Journal Camshaft Journal-Clearance, Plastigage Method NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. 1. Remove the camshaft bearing cap. 2. Lay Plastigage across the face of the camshaft bearing surface. 3. Position the camshaft bearing cap and install the bolts in the sequence indicated. NOTE: Do not turn the camshaft while doing this procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal > Page 2452 4. Use Plastigage to verify the camshaft journal clearance - If it is out of specification, replace as necessary. Diameter 1. Measure each camshaft journal diameter in two directions. - If it is out of specification, replace as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal > Page 2453 Camshaft: Testing and Inspection Lobe Lobe Lift 1. Use a Dial Indicator with Bracketry to measure camshaft intake lobe lift. - Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading to figure the camshaft lobe lift. 2. Use a Dial Indicator with Bracketry to measure camshaft exhaust lobe lift. - Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading to figure the camshaft lobe lift. Lobe Surface 1. Inspect camshaft lobes for pitting or damage in the active area. Minor pitting is acceptable outside the active area. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal > Page 2454 Camshaft: Testing and Inspection End Play 1. Remove the roller followers. 2. Use a Dial Indicator to Bracketry to measure camshaft end play. 3. Position the camshaft to the rear of the cylinder head. 4. Zero the indicator. 5. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. - If camshaft end play exceeds specifications, replace the camshaft thrust bearing washers. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal > Page 2455 Camshaft: Testing and Inspection Runout 1. Use a the Dial Indicator with Bracketry to measure the camshaft runout. - Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading. NOTE: Camshaft journals must be within specifications before checking Snout. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Page 2456 Camshaft: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Remove the timing chain/belts. 4. Remove the six bolts retaining the balance shaft bearing caps and remove the bearing caps. 5. Remove the balance shaft. 6. Use the Valve Spring Compressor to compress the valve springs and install the camshaft roller followers. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Page 2457 7. Remove the bolts, the camshaft bearing caps and the camshaft from the cylinder block. INSTALLATION 1. Lubricate the camshaft journals. - Use Super Premium SAE 5W30 Motor Oil D9AZ-19579-A or equivalent meeting Ford specification WSS-M2C153-G. 2. Install the camshaft and the camshaft bearing caps onto the cylinder head. Loosely install the fifteen bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Page 2458 3. Tighten the bolts in the sequence shown. 4. Use the Valve Spring Compressor to compress the valve springs and install the camshaft roller followers. 5. Lubricate the balance shaft journals with engine oil. - Use Super Premium SAE 5W30 Motor Oil D9AZ-19579-A or equivalent meeting Ford specification WSS-M2C153-G. 6. Position the balance shaft on the journals. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Page 2459 7. Align the balance shaft timing marks as shown. 8. Position the bearing caps and the bolts and tighten in the sequence shown. 9. Install the intake manifold. 10. Install the timing chain/belts. 11. Connect the battery around cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Page 2460 Camshaft: Tools and Equipment Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Leakdown Test Lifter / Lash Adjuster: Testing and Inspection Leakdown Test 1. Compress the valve tappet to remove the engine oil if necessary. NOTE: The leakdown test will not be accurate if it is done with engine oil in the valve tappet. Use testing fluid. New valve tappets are already filled with testing fluid. 2. Place the (A) valve tappet in a (B) commercially available hydraulic tappet leakdown tester. Position the (C) steel ball provided in the plunger cap. Add testing fluid to cover the valve tappet and compress the hydraulic tappet leakdown tester until the valve tappet is filled with testing fluid. 3. Adjust the length of the (A) ram so that the (B) pointer is just below the (C) start timing mark when the ram contacts the valve tappet. Start timing as the pointer passes the (C) start timing mark and end timing as the pointer reaches the (D) center mark. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Leakdown Test > Page 2465 Lifter / Lash Adjuster: Testing and Inspection Roller Follower Inspection 1. Inspect the roller for flat spots or scoring. If any damage is found, inspect the camshaft lobes and valve tappet for damage. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold Rocker Arm Assembly: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold > Page 2474 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold > Page 2475 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2481 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2482 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rocker Arm Assembly: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rocker Arm Assembly: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2488 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rocker Arm Assembly: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2489 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rocker Arm Assembly: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2495 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rocker Arm Assembly: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2496 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Specifications Balance Shaft: Specifications GENERAL SPECIFICATIONS Balance Shaft Journal Diameter ........................................................................................................................................................... 26.962-26.936 mm Clearance-Balance Shaft Journal to Cylinder Head ................................................................................................................................. 0.076-0.025 mm Cylinder Head B/S Journal Diameter ................................................................................................................................................... 27.012-26.987 mm Gear Backlash ...................................................................................................... ................................................................................ 0.0076-0.1295 mm Balance Shaft Endplay ........ .............................................................................................................................................................. ........... 0.04-0.18 mm Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing to Journal Clearance 0.064-0.026 mm Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 2504 Connecting Rod Bearing: Testing and Inspection 1. Inspect bearings for the following defects. Possible causes are shown: - cratering-fatigue failure (A) - spot polishing-improper seating (B) - scratching-dirty (C) - base exposed-poor lubrication (D) - both edges worn-journal damaged (E) - one edge worn-journal tapered or bearing not seated (F) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt Connecting Rod: Specifications Connecting Rod Bolts Stage 1 40-45 Nm (30-33 ft.lb) Be sure to tighten bolts in two stages. Stage 2 Additional 90°-120° Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 2509 Connecting Rod: Specifications Connecting Rod, Engine GENERAL SPECIFICATIONS Pin Bore Diameter (Rod) ..................................................................................................................... ................................................ 22.012-22.024 mm Clearance ............................................................ ................................................................................................................................... 0.009-0.0235 mm Big End Journal Inside Diameter with Assembled Liners .................................................................................................................... 53.049-53.027 mm Rod Bearing to Journal Clearance ........................................................................................................................................................... 0.064-0.026 mm Rod Length (Centerline Bore-to-Bore) .............................................................................................................................................................. 169.1 mm Alignment Bore-to-Bore Max. Twist ...................................................................................................................... ...................................................... ± 0.05 mm Bore-to-Bore Max. Bend ............................................. ............................................................................................................................. ± 0.038 mm Side Play (As Assembled to Crank) Standard Play ...................................................................................................................................... .............................................. 0.410 ± 0.26 mm Max. Play .................................................................. ................................................................................................................................... 0.670 mm Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance Connecting Rod: Testing and Inspection Connecting Rod Bearing Journal Clearance 1. Remove the connecting rod bearing cap. NOTE: The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearance. 2. Position a piece of Plastigage across the bearing surface. 3. Install and tighten to specifications, then remove the connecting rod bearing cap. NOTE: Do not turn the crankshaft during this step. 4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should be smooth and flat. A changing width indicates a tapered or damaged connecting rod or connecting rod bearing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2512 Connecting Rod: Testing and Inspection 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. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2513 Connecting Rod: Testing and Inspection Connecting Rod Bushing Diameter 1. Measure the inner diameter of the connecting rod bushing. Verify the diameter is within specification. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2514 Connecting Rod: Testing and Inspection Connecting Rod Cleaning CAUTION: Do not use a caustic cleaning solution or damage to connecting rods can occur. 1. Mark and separate the parts and clean with solvent. Clean the oil passages. NOTE: The connecting rod large end is mechanically split or cracked to produce a unique parting face. This produces a locking joint. Parts are not interchangeable Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2515 Connecting Rod: Testing and Inspection Connecting Rod Bearing Journal Clearance 1. Remove the connecting rod bearing cap. NOTE: The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearance. 2. Position a piece of Plastigage across the bearing surface. 3. Install and tighten to specifications, then remove the connecting rod bearing cap. NOTE: Do not turn the crankshaft during this step. 4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should be smooth and flat. A changing width indicates a tapered or damaged connecting rod or connecting rod bearing. 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 Bushing Diameter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2516 1. Measure the inner diameter of the connecting rod bushing. Verify the diameter is within specification. Connecting Rod Cleaning CAUTION: Do not use a caustic cleaning solution or damage to connecting rods can occur. 1. Mark and separate the parts and clean with solvent. Clean the oil passages. NOTE: The connecting rod large end is mechanically split or cracked to produce a unique parting face. This produces a locking joint. Parts are not interchangeable Connecting Rod Large End Bore 1. Measure the bore in two directions. The difference is the connecting rod bore out-of-round. Verify the out-of-round is within specification. Connecting Rod Piston Pin Side Clearance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2517 1. Measure the clearance between the connecting rod and the piston. Verify the 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. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications TORQUE SPECIFICATIONS Cylinder Drain Plug .............................................................................................................................. ..................................... 16-24 Nm (12-18 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Testing and Inspection > Gears Crankshaft Gear/Sprocket: Testing and Inspection Gears 1. Inspect the (A) camshaft thrust plate, the (B) cam gear and the (C) crank gear. - Replace as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Testing and Inspection > Gears > Page 2525 Crankshaft Gear/Sprocket: Testing and Inspection Sprockets 1. Inspect the (A) timing chain/belt and the (B) sprockets. - Replace as necessary. WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHICLE, DO NOT OPERATE THE ENGINE WITH THE HOOD OPEN UNTIL THE FAN BLADE HAS BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION. NOTE: Specifications show the expected minimum or maximum condition. - If a component fails to meet the specifications, it is necessary to replace or refinish. If the component can be refinished, wear limits are provided as an aid to making a decision. Any component that fails to meet specifications and cannot be refinished must be replaced. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Main Bearing Cap Bolts (Fasteners 1-12) Stage 1 37-43 Nm Stage 2 Additional 85-95 degrees Main Bearing cap Bolts (Fasteners 13-24) Stage 1 27-33 Nm Stage 2 Additional 85-95 degrees Crankshaft Main Bearing Journal Diameter 67.482-67.504 mm Maximum Out-of-Round 0.0075 mm between cross sections Maximum Taper (Straightness) 0.004 mm Runout: FIM of center journals when located on front and rear 0.05 mm (3 places) journal Clearance - Crankshaft Journal to Main Bearing Clearance 0.048-0.024 mm Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2529 Crankshaft Main Bearing: Testing and Inspection 1. Inspect bearings for the following defects. Possible causes are shown: - cratering-fatigue failure (A) - spot polishing-improper seating (B) - scratching-dirty (C) - base exposed-poor lubrication (D) - both edges worn-journal damaged (E) - one edge worn-journal tapered or bearing not seated (F) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications GENERAL SPECIFICATIONS Main Bearing Journal Diameter ........................................................................................................... ....................................................... 67.482-67.504 Maximum Out-of-Round ........................................................................................................................................... 0.0075 mm Between Cross Sections Maximum Taper (Straightness) ................................................................... ....................................................................................................... 0.004 mm Runout: FIM of center journals when located on front and rear journal .................................................................................................................... TBD Clearance-Crankshaft Journal to Main Bearing Clearance ...................................................................................................................... 0.048-0.024 mm Connecting Rod Journal Diameter ....................................................................................................................................................... 53.003-52.983 mm Maximum Out-of-Round ........................................................................................................................................... 0.0075 mm Between Cross Sections Maximum Taper .......................................................................................... ....................................................................................................... 0.004 mm Crankshaft End Play ... .............................................................................................................................................................. ...................... 0.075-0.377 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > End Play Crankshaft: Testing and Inspection End Play 1. Measure the crankshaft end play. Use a Dial Indicator with Bracketry to measure 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. - If crankshaft end play exceeds specifications, replace the crankshaft thrust washer or crankshaft thrust main bearing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > End Play > Page 2535 Crankshaft: Testing and Inspection Journal Connecting Rod Journal Diameter 1. Measure the crankshaft connecting rod journal diameters in at least two directions perpendicular to one another. The difference between the measurements is the out-of-round. Verify the journal is within the wear limit specification. Connecting Rod Journal Taper 1. Measure the crankshaft connecting rod journal diameters in two 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 Main Bearing Journal Clearance 1. Remove the crankshaft main bearing caps and crankshaft main bearing. NOTE: Crankshaft main bearing journals must be within specifications before checking journal clearance. 2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface. 3. Install and remove the crankshaft main bearing cap. NOTE: Do not turn the crankshaft while doing this procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > End Play > Page 2536 4. Verify the crankshaft journal clearance. - If it is out of specification, replace as necessary. Main Bearing Journal Diameter 1. Measure each of the crankshaft main bearing journal diameters in at least two directions. - If it is out of specification, replace as necessary. Main Bearing Journal Taper 1. Measure each of the crankshaft main bearing journal diameters in at least two directions at each end of the main bearing journal. - If it is out of specification, replace as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > End Play > Page 2537 Crankshaft: Testing and Inspection Runout 1. Use the Dial Indicator with Bracketry 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. If it is out of specification, replace as necessary. NOTE: Crankshaft main bearing journals must be within specifications before checking runout. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > Page 2538 Crankshaft: Tools and Equipment Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair Expansion/Freeze Plug: Service and Repair 1. Use a slide hammer or tools suitable to remove the cylinder block core plug. 2. Inspect the cylinder block plug bore for any damage that would interfere with the proper sealing of the plug. If the cylinder block plug bore is damaged, bore for the next oversize plug. 3. Coat the cylinder block core plug and bore lightly with Thread lock262 E2FZ-19554B or equivalent meeting Ford specification WSK-M2G351-A6 and install the cylinder block core plug. NOTE: Oversize plugs are identified by the OS, stamped in the flat located on the cup side of the plug. CUP-TYPE 1. Use a fabricated tool to seat the cup type cylinder block core plug. CAUTION: Do not contact the flange when installing a cup type cylinder block core plug. This could damage the sealing edge and result in leakage. - When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore. EXPANSION-TYPE 1. Use a fabricated tool to seat the expansion type cylinder block core plug. CAUTION: Do not contact the crown when installing an expansion type cylinder block core plug. This could expand the plug before seating and result in leakage. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair > Page 2542 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Front Engine Plate > Component Information > Service and Repair > Removal Front Engine Plate: Service and Repair Removal WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 1. Disconnect the battery ground cable 2. Remove the valve covers. 3. Remove the radiator. 4. Disconnect the Camshaft Position Sensor (CMP sensor). 5. Remove the water pump. 6. Raise and support the vehicle. 7. Remove the bolts and position the power steering pump aside. NOTE: Only three bolts are required to secure the power steering pump. 8. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 9. Remove the drain plug and drain the engine oil. 10. Remove the crankshaft front seal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Front Engine Plate > Component Information > Service and Repair > Removal > Page 2547 11. Remove the bolts. 12. Lower the vehicle. 13. Remove the engine timing cover fasteners. 14. Remove the engine timing cover from the front cover to cylinder block dowels. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Front Engine Plate > Component Information > Service and Repair > Removal > Page 2548 Front Engine Plate: Service and Repair Installation 1. Install a new engine timing cover gasket on the engine timing cover, then position the engine timing cover on the front cover to cylinder block dowels. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Front Engine Plate > Component Information > Service and Repair > Removal > Page 2549 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Front Engine Plate > Component Information > Service and Repair > Removal > Page 2550 2. Loosely install the cover fasteners. 3. Tighten the fasteners in two stages following the sequence shown. - Stage 1: Tighten fasteners 1 through 5 to 20-30 Nm (15-22 ft. lbs.) - Stage 2: Tighten fasteners 6 through 15 to 40-55 Nm (30-41 ft. lbs.) 4. Tighten the bolts in the sequence shown. - Stage 1: Tighten to 20 Nm (15 ft. lbs.) - Stage 2: Tighten an additional 60 degrees NOTE: Be sure to tighten the bolts in two stages. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Front Engine Plate > Component Information > Service and Repair > Removal > Page 2551 5. Connect the CKP sensor electrical connector. 6. Install the bolts. 7. Lower the vehicle. 8. Install the water pump. 9. Connect the CMP electrical connector. 10. Raise and support the vehicle. 11. Install a new crankshaft front seal and the crankshaft pulley. 12. Lower the vehicle. 13. Install the valve covers. 14. Install the radiator and fill the cooling system. 15. Install the engine Air Cleaner (ACL) and the air cleaner outlet tube. 16. Connect the battery ground cable. 17. Fill the engine with oil. - Use engine oil meeting Ford specification WSS-M2C153-G. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Step 1 90 Nm (66 ft.lb) Step 2 Loosen 360° Step 3 47-53 Nm (34-39 ft.lb) Step 4 Additional 85°-95° Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2555 Harmonic Balancer - Crankshaft Pulley: Service and Repair REMOVAL 1. Remove the engine cooling fan and fan shroud. 2. Remove the drive belt. 3. Raise the vehicle on a hoist. 4. Remove the crankshaft pulley bolt. 5. Using the Crankshaft Damper Remover, remove the crankshaft pulley. INSTALLATION 1. Apply silicone to the Woodruff key slot in the crankshaft pulley. - Use Silicone Gasket and Sealant F6AZ-19562-A or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. 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. 2. Use the Crankshaft Damper Replacer to install the crankshaft pulley. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2556 3. Tighten the crankshaft pulley bolt in four stages. - Stage 1: Tighten to 90 Nm (66 ft. lbs.) - Stage 2: Loosen 360 degrees - Stage 3: Tighten to 47-53 Nm (35-39 ft. lbs.) - Stage 4: Tighten an additional 85-95 degrees 4. Lower the vehicle. 5. Install the upper radiator hose. 6. Install the engine cooling fan and the fan shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications GENERAL SPECIFICATIONS Piston Diameter (Grade 2) at Right Angle to Pin Bore ....................................................................................................................... 90.180 ± 0.005 mm Piston to Bore Clearance ..................................................................................................................... ........................................... (-0.005) to +0.025 mm Pin Bore Diameter (Piston) ................................. ................................................................................................................................. 22.008-22.014 mm Pin Clearance (Neg. or Pos.) ........................................................................................................ ........................................................ 0.01395-0.005 mm Ring Groove Width Top ...................................................................................................................................................... ............................................... 1.503-1.505 mm Intermediate ............................................................. .......................................................................................................................... 1.502-1.504 mm Oil Control ............................................................................................................................................ ................................................... 3.030-3.050 mm Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Diameter Piston: Testing and Inspection Diameter 1. Measure the piston skirt diameter as indicated. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Diameter > Page 2562 Piston: Testing and Inspection Inspection 1. Clean and inspect the (A) ring lands, (B) skirts, (C) pin bosses, and the (D) tops of the pistons. If wear marks or polishing is found on the piston skirt, check for a bent or twisted connecting rod. CAUTION: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can occur. 2. Use the Piston Ring Groove Cleaner to clean the piston ring grooves. - Make sure the oil ring holes are clean. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Diameter > Page 2563 Piston: Testing and Inspection Pin Bore Diameter 1. Measure the piston pin bore diameter in two directions on each side. Verify the diameter is within specification. WARNING: COVER THE END OF THE PIN BORE WITH A HAND OR SHOP RAG WHEN REMOVING THE RETAINER RING, SINCE IT HAS A TENDENCY TO SPRING OUT. WEAR EYE PROTECTION. NOTE: Piston and piston pins are a matched set and should not be interchanged. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Diameter > Page 2564 Piston: Testing and Inspection Piston to Cylinder Bore Clearance 1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore clearance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Diameter > Page 2565 Piston: Testing and Inspection 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. 2. Choose the piston with the proper paint color. - red-in the lower third of the size range - blue-in the middle third of the size range - yellow-in the upper third of the size range Note: For precision fit, new pistons are divided into three categories within each size range based on their relative position within the range. A paint spot on the new pistons indicates the position within the size range. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Page 2566 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications GENERAL SPECIFICATIONS Pin Diameter ........................................................................................................................................ ............................................ 22.0005-22.0030 mm Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 2570 Piston Pin: Testing and Inspection 1. Measure the piston pin diameter in two directions at the points shown. Verify the diameter is within specification. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications GENERAL SPECIFICATIONS Piston Ring Gap Top ...................................................................................................................................................... ................................................... 0.13-0.28 mm Intermediate ............................................................. .............................................................................................................................. 0.25-0.40 mm Oil Control ............................................................................................................................................ ....................................................... 0.15-0.65 mm Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Testing and Inspection > End Gap Piston Ring: Testing and Inspection End Gap CAUTION: - Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore. - Piston rings should not be transferred from one piston to another. 1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel. NOTE: Cylinder bore must be within specification for taper and out-of-round to fit piston rings. 2. Use a feeler gauge to measure the top piston ring end gap and the second piston ring end gap. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Testing and Inspection > End Gap > Page 2576 Piston Ring: Testing and Inspection Ring to Groove Clearance 1. Inspect for a step in the grooves. 2. Measure the piston ring-to-groove clearance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Testing and Inspection > Page 2577 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 EFI/CFI Fuel Pressure Gauge WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the fuel pressure gauge. 2. Slowly open the manual valve on the fuel pressure gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place fuel in a suitable container. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2593 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2594 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2600 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2601 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications TORQUE SPECIFICATIONS Valve Cover Bolts ................................................................................................................................ .................................. 8-12 Nm (71-106 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side Valve Cover: Service and Repair Right Side REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 1. Remove the intake manifold. 2. Remove clamp and oil filler hose from the valve cover. 3. Remove the valve cover. 1 Fully loosen the bolts, and remove the valve cover and the valve cover gasket. NOTE: The bolts are a part of the valve cover and are not to be removed. INSTALLATION 1. Clean and inspect the mating surface of the cylinder block. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools causes scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. 2. Apply silicone in two places where the engine timing cover meets the cylinder head. - Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2607 equivalent meeting Ford specification WSE-M5B392-A. 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. 3. Position the valve cover on the cylinder head and loosely install the bolts. 4. Tighten the bolts in the sequence shown. 5. Install the oil filler tube and clamp on the valve cover. 6. Install the intake manifold. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2608 Valve Cover: Service and Repair Left Side REMOVAL 1. Remove the intake manifold. 2. Fully loosen the valve cover. - Remove the two nuts and the sixteen bolts, and remove the valve cover and the valve cover gasket. NOTE: The bolts are a part of the valve cover and are not to be removed. INSTALLATION 1. Clean and inspect the mating surfaces of the cylinder head. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. 2. Apply silicone in two places where the engine timing cover meets the cylinder head. - Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. 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. 3. Position the valve cover and the valve cover gasket on the cylinder head and loosely install the bolts and nuts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2609 4. Tighten the nuts and bolts in the sequence shown. 5. Install the intake manifold. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications GENERAL SPECIFICATIONS Valve Guide Inside Diameter ............................................................................................................... .................................................... 7.044-7.015 mm Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Testing and Inspection > Inner Diameter Valve Guide: Testing and Inspection Inner Diameter 1. Measure the inner diameter of the valve guides in two directions where indicated. 2. If the valve guide is not within specifications, ream the valve guide and install a valve with an oversize stem or remove the valve guide and install a new valve guide. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Testing and Inspection > Inner Diameter > Page 2615 Valve Guide: Testing and Inspection Valve Guide Reaming 1. Use a hand-reaming kit to ream the valve guide. 2. Reface the valve seat. 3. Clean the sharp edges left by reaming. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications GENERAL SPECIFICATIONS Valve Seat Width Intake ................................................................................................................................................... ...................................................... 2.1-1.9 mm Exhaust ..................................................................... ................................................................................................................................. 2.1-1.9 mm Valve Seat Angle ................................................................................................................................. .............................................. 45.00-44.50 degrees Valve Seat Runout (T.I.R) .................................. ............................................................................................................................................... 0.025 mm Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Testing and Inspection > Inspection Valve Seat: Testing and Inspection Inspection 1. Check the valve seat and valve angles. Caution: After grinding valves or valve seats, check valve clearance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Testing and Inspection > Inspection > Page 2621 Valve Seat: Testing and Inspection Runout 1. Use the Valve Seat Runout Gauge to check valve seat runout. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Testing and Inspection > Inspection > Page 2622 Valve Seat: Testing and Inspection 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. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications GENERAL SPECIFICATIONS Valve Spring Compression Pressure Intake ................................................................................................................................................... ...................................... 667.3 N @ 28.02 mm Exhaust ..................................................................... ................................................................................................................. 667.3 N @ 28.02 mm Valve Spring Free Length Intake ................................................................................................................................................... ........................................................... 50.2 mm Exhaust ..................................................................... ...................................................................................................................................... 50.2 mm Valve Spring Installed Pressure Intake ................................................................................................................................................... ...................................... 289.1 N @ 40.01 mm Exhaust ..................................................................... ................................................................................................................. 289.1 N @ 40.01 mm Valve Springs Installed Pressure - Service Limit Intake ................................................................................................................................................... ................................... 274.6 mm @ 40.01 mm Exhaust ..................................................................... .............................................................................................................. 274.6 mm @ 40.01 mm Valve Springs - Out of Square Limit Intake ................................................................................................................................................... ...................................................... 2.5 degrees Exhaust ..................................................................... .................................................................................................................................. 2.5 degrees Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length Valve Spring: Testing and Inspection Free Length 1. Measure the free length of each valve spring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length > Page 2628 Valve Spring: Testing and Inspection Installed Length 1. Measure the installed length of each valve spring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length > Page 2629 Valve Spring: Testing and Inspection 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. Replace the valve spring if out of specification. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length > Page 2630 Valve Spring: Testing and Inspection Strength 1. Use a Valve/Clutch Spring Tester to check the valve spring for proper strength at the specified valve spring length. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Page 2631 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold Valve: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold > Page 2640 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold > Page 2641 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Valve: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2647 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2648 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Page 2649 Valve: Specifications GENERAL SPECIFICATIONS Valve Stem Guide Clearance Intake ................................................................................................................................................... .............................................. 0.069-0.020 mm Exhaust ..................................................................... ......................................................................................................................... 0.095-0.045 mm Valve Head Diameter Intake ................................................................................................................................................... ............................................. 44.63-44.37 mm Exhaust ...................................................................... ........................................................................................................................ 34.12-33.88 mm Valve Face Runout (Limit) ................................................................................................................... ................................................................ 0.05 mm Valve Face Angle ................................................ ............................................................................................................................... 45.75-45.25 degrees Valve Stem Diameter Intake ................................................................................................................................................... .............................................. 6.995-6.975 mm Exhaust ..................................................................... ......................................................................................................................... 6.970-6.949 mm Valve Stem Diameter (List Oversizes) Intake ................................................................................................................................................... .................................................................. N/A Exhaust ...................................................................... ............................................................................................................................................ N/A Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection Valve: Testing and Inspection Inspection 1. Inspect the following valve areas: - the end of the stem for grooves or scoring (A) - the valve face and the edge for pits, grooves or scores (B) - the valve head for signs of burning, erosion, warpage and cracking. Minor pits, grooves and other abrasions may be removed (C) - the valve head thickness for wear (D) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection > Page 2652 Valve: Testing and Inspection Stem Diameter 1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection > Page 2653 Valve: Testing and Inspection Stem to Guide Clearance NOTE: Valve stem diameter must be within specifications before checking valve stem to valve guide clearance. 1. Install a Valve Stem Clearance Tool on the valve stem and install a Dial Indicator with Bracketry. Lower the valve until the Valve Stem Clearance Tool contacts the upper surface of the valve guide. NOTE: If necessary, use a magnetic base. 2. Move the Valve Stem Clearance Tool toward the indicator and zero the indicator. Move the Valve Stem Clearance Tool away from the indicator and note the reading. The reading will be double the valve stem-to-valve guide clearance. Valves with oversize stems will need to be installed if out of specification. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Page 2654 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2659 Drive Belt: Description and Operation Part 1 Of 2 Part 2 Of 2 Ford vehicles are equipped with a poly-vee drive belt. To ensure maximum belt life, replacement drive belts must be of the same type and specification as originally installed. The drive belt is tensioned by a spring-loaded tensioner that maintains proper belt tension at all times. A loose drive belt will result in slippage, which can cause a noise complaint or improper accessory operation Generator (GEN) will not charge, etc. An overly tight drive belt will place severe loads on accessory bearings and result in premature drive belt or accessory failure. Refer to the illustrations for the belt routing of each particular engine. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2662 Drive Belt: Component Tests and General Diagnostics Belt Tension The drive belt tensioner automatically adjusts drive belt tension. NOTE: The drive belt tension is not adjustable. Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and can cause the drive belt to come off the drive pulleys. Non-standard replacement drive belts can track differently or improperly. If a replacement drive belt tracks improperly, replace it with an original equipment drive belt to avoid performance failure or loss of belt. When the engine running, check drive belt tracking. If the (A) edge of the drive belt rides beyond the edge of the pulleys, noise and premature wear can occur. Make sure the (B) drive belt rides correctly on the pulley. If a drive belt tracking condition exists, follow the procedures below: - Visually check the drive belt tensioner for damaged, especially the mounting pad surface. If the drive belt tensioner is not installed correctly with the dowels in the mounting bracket holes (4.2L only), the mounting surface pad will be out of position. This will result in chirp and squeal noises. - With the engine running, visually observe the front surface grooves in the pulleys (not the pulley flanges) for excessive wobble. Replace components as required. - Check all accessories, mounting brackets and the drive belt tensioner for any interference preventing the components from mounting properly. Correct any interference condition and recheck belt tracking. - Tighten all accessories, generator mounting brace and drive belt tensioner retaining hardware to specification. Recheck the drive belt tracking. Drive Belt Noise/Flutter Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged pulley of and improperly aligned pulley. To correct, determine the area 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 is an intermittent noise that occurs when the drive belt slips on a pulley during certain conditions, such as engine start-up, rapid engine acceleration or A/C clutch engagement. Drive belt squeal can occur under the following conditions: 1. The A/C discharge pressure goes above specifications, causing one of the following: - The A/C system is overcharged. - The A/C condenser core airflow is blocked. 2. The A/C OFF equalized pressure (the common discharge and suction pressure that occurs after several minutes) exceeds specifications. 3. Any of the accessories are damaged or have a worn or damaged bearing or internal torsional resistance above normal. All accessories must be rotatable by hand in the unloaded condition. If not, inspect the accessory. 4. Fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air conditioning system lubricant. If fluid gets on the drive belt during repairs, clean the drive belt with soap and water, and thoroughly rinse with clean water.The drive belt does not have to be replaced if no apparent damage had occurred. 5. The drive belt is too long. A drive belt that is too long will allow the 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 drive belt tensioner indicator is outside of the wear range window, replace the drive belt. NOTE: The drive belt tensioner arm must rotate freely without binding. 6. The drive belt tensioner is worn or damaged. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2663 Drive Belt Wear V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) Under severe operating conditions (high temperatures, low humidity), drive belt rib cracking can occur at less than 48,000 km (30,000 miles). Drive belt rib cracking had no effect on belt performance. Drive belt "chunking" describes a condition in which the rubber material actually chunks out between the rib cracks. The drive belt must be replaced if chunking occurs. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications TORQUE SPECIFICATIONS Belt Tensioner ..................................................................................................................................... ....................................... 20-30 Nm (15-22 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2667 Drive Belt Tensioner: Description and Operation The drive belt tensioner will maintain correct belt tension if the correct length drive belt is on the engine. To verify that the drive belt tensioner is working properly, check to see that the belt length indicator mark on the drive belt tensioner is between the minimum and maximum marks. Remove the drive belt and rotate the tensioner from stop to stop to verify that the tensioner does not stick, grab or bind. If the tensioner exhibits any of these conditions, replace the tensioner. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2668 Drive Belt Tensioner: Testing and Inspection CAUTION: The drive belt tensioner has no provision for adjustment and will be damaged if forced to travel beyond its operating range. Check the automatic drive belt tensioner: 1. With the engine off, check for proper drive belt routing. 2. Rotate the drive belt tensioner and check for a binding or frozen condition. Replace components as required. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2669 Drive Belt Tensioner: Service and Repair REMOVAL 1. Remove the drive belt. 2. Remove the (A) bolts and the (B) drive belt tensioner from the engine timing cover. NOTE: The fan and fan clutch are removed for clarity. - The drive belt tensioner with air conditioning is shown. The drive belt tensioner for vehicles without air conditioning is similar. INSTALLATION 1. Follow the removal procedures in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2674 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2675 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2676 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2677 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2678 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2679 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2680 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2681 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2682 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2683 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2684 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2685 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2686 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2687 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2688 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2689 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2690 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2691 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2692 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2693 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2694 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2695 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2696 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2697 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2698 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2699 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2700 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2701 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2702 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2703 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2704 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2705 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2706 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2707 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2708 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2709 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2710 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2711 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2712 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2713 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2714 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2715 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2716 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2717 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2718 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2719 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2720 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2721 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2722 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2723 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2724 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2725 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2726 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2727 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2728 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2729 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2730 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2731 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2732 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2733 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2734 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2735 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2736 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2737 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2738 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2739 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2740 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2741 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2742 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2743 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2744 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2745 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2746 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2747 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2748 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2749 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2750 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2751 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2752 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2753 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2754 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2755 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2756 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2757 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2758 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2759 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2760 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2761 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2762 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2763 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2764 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2765 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2766 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2767 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2768 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 2769 Engine Mount: Specifications TORQUE SPECIFICATIONS Motor Mount Pivot Bolt ............................................................................................................................................................. 68-92 Nm (50-68 ft. lbs.) Motor Mount to Engine Bolts .................................................................................................................................................... 52-71 Nm (38-52 ft. lbs.) Front Engine Support Insulator .................................................................................................................................................. 68-92 Nm (50-68 ft. lbs.) Engine Support Insulator Bolts ............................................................................................................................................................. 80 Nm (59 ft. lbs.) Engine Support Insulator Nuts .............................................................................................................................................................. 90 Nm (66 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 2770 Engine Mount: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the vapor management valve. 3. Remove the throttle body. 4. Partially drain the cooling system and disconnect the upper radiator hose at the radiator. 5. Remove the two upper screws and position the fan shroud toward the engine. 6. Remove the nut retaining the transmission oil filler tube and position the tube aside. 7. Raise the vehicle. 8. Remove the nuts retaining the front engine support insulators to the engine support brackets. - The RH is shown; the LH is similar. 9. For the RH front engine support insulator, remove the starter motor. 10. Position two screw jacks under the left and right rear oil pan rails and raise the engine. 11. Remove the bolts and remove the front engine support insulators from the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 2771 NOTE: Engine is not shown for clarity. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications TORQUE SPECIFICATIONS Idler Pulley Bolt .................................................................................................................................... ..................................... 20-30 Nm (15-22 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications > Page 2775 Idler Pulley: Service and Repair REMOVAL 1. Remove the drive belt. 2. Remove the (A) bolt and the (B) belt idler pulley from the engine timing cover. INSTALLATION 1. Follow the removal procedures in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Factory information does not provide an oil pressure specification for this vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications TORQUE SPECIFICATIONS Oil Level Indicator Bracket Nut ................................................................................................................................................. 20-30 Nm (15-22 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 2783 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair REMOVAL 1. Remove the engine Air Cleaner (ACL) and the air cleaner outlet tube. 2. Remove the oil level dipstick and the nut retaining the oil level indicator tube and bracket assembly. 3. Remove the left exhaust manifolds. 4. Remove the bolt and remove the oil level indicator tube. 5. Inspect the oil level indicator tube for damage. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 2784 1. Follow the removal procedure in reverse order. 2. Replace and lubricate the O-rings with Super Premium SAE 5W30 Motor Oil D9AZ-19579-A or equivalent meeting Ford specification WSS-M2C153-G. 3. Install the left exhaust manifold. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2789 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2790 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2791 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2792 Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 5.7L (6.0 Qt) NOTE: Listed capacities are approximate. Check fluid level after filling. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2795 Engine Oil: Fluid Type Specifications Engine Oil Type Type ..................................................................................................................................................... .......................................................................... GF-3 Viscosity .............................................................................................................................................. ...................................................................... 5W-20 NOTE: Must meet Ford Specification WSS-M2C-153-H Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications Oil Cooler: Specifications TORQUE SPECIFICATIONS Oil Cooler to Adapter ............................................................................................................................................................. 55-60 Nm (41-44 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications TORQUE SPECIFICATIONS Oil Filter ............................................................................................................................................... ........................... 14-17 Nm (125-151.6 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications TORQUE SPECIFICATIONS Oil Filter Adapter Assembly Bolts ............................................................................................................................................. 20-30 Nm (15-22 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications > Page 2805 Oil Filter Adapter: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Remove the left engine support insulator. 4. Remove the lower radiator hose. 5. Drain the engine oil and remove the oil bypass filter. 6. Loosen the threaded tube and remove the oil cooler from the oil filter adapter. 7. Remove one nut and two bolts and remove the oil filter adapter from the cylinder block. 8. Remove the old oil filter adapter gasket and clean the gasket surface at the cylinder block. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications > Page 2806 1. Follow the removal procedure in reverse order. 2. Fill the engine cooling system. 3. Fill the crankcase with Motorcraft Engine Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal Oil Pan: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the throttle body. 3. Remove the vapor management valve. 4. Partially drain the radiator and disconnect the upper radiator hose at the radiator. 5. Remove the two screws at the top of the fan shroud and position the fan shroud toward the engine. 6. Remove the nut retaining the transmission filler tube at the rear of the RH cylinder head and position the tube aside. 7. Raise and support the vehicle. 8. Drain the engine oil and remove the oil bypass filter. 9. Remove the nuts retaining the front engine support insulator to the front engine support bracket. The RH is shown, the LH is typical. 10. Remove the flywheel inspection plate. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal > Page 2811 11. Position two screw jacks under the left and right rear oil pan rails and raise the engine. 12. Raise the engine to the ideal working height as shown. 13. Position the wood blocks between the engine supports and the engine support lower bracket. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal > Page 2812 14. Lower the engine onto wood blocks. 15. Remove the bolts and partially lower the oil pan. 16. Remove the two bolts and the nut retaining the oil pump screen cover and tube and let them drop into the oil pan. 17. Remove the oil pan and oil pan gasket from the rear of the engine. 18. Clean the mating surfaces and thoroughly clean the oil pan. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal > Page 2813 Oil Pan: Service and Repair Installation 1. Install the oil pump screen cover and tube. 2. Apply a bead of silicone where the front cover an the rear crankshaft seal retainer fit to the engine block. - Use Silicone Gasket and Sealant F6AZ-19562-A or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned wit Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A. 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. 3. Tighten the bolts in the sequence shown. - Stage 1: Tighten to 2 Nm (18 inch lbs.) - Stage 2: Tighten to 20 Nm (15 ft. lbs.) - Stage 3: Tighten an additional 60 degrees NOTE: Be sure to tighten the bolts in three stages. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal > Page 2814 4. Tighten the front engine support insulators. 5. Connect the battery ground cable. 6. Fill the engine with oil. - Use Motorcraft Engine Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 7. Fill the cooling system Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection For Testing of this and other gauges, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Panel, Testing and Inspection. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications > Oil Pump Pick Up Oil Pick Up/Strainer: Specifications Oil Pump Pick Up TORQUE SPECIFICATIONS Oil Pump Screen Cover and Tube Bolts ................................................................................................................................. 8-12 Nm (71-106 inch lbs.) Oil Pump Screen and Cover Assembly Spacer .......................................................................................................................... 20-30 Nm (15-22 ft. lbs.) Oil Pump Screen Cover and Tube Nuts ..................................................................................................................................... 20-30 Nm (15-22 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications > Oil Pump Pick Up > Page 2822 Oil Pick Up/Strainer: Specifications Oil Strainer, Engine TORQUE SPECIFICATIONS Oil Pump Screen Cover and Tube Bolts ................................................................................................................................. 8-12 Nm (71-106 inch lbs.) Oil Pump Screen and Cover Assembly Spacer .......................................................................................................................... 20-30 Nm (15-22 ft. lbs.) Oil Pump Screen Cover and Tube Nuts ..................................................................................................................................... 20-30 Nm (15-22 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Factory information does not provide an oil pressure specification for this vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Lower Intake to Upper Intake Bolts Step 1 2 Nm (18 in.lb) Step 2 8-12 Nm (71-106 in.lb) Upper Intake to Cylinder Head Bolts Step 1 2 Nm (18 in.lb) Step 2 20-30 Nm (15-22 ft.lb) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2830 Intake Manifold: Diagrams Engine Intake Components, Part 1 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2831 Engine Intake Components, Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Intake Manifold Vacuum Test Intake Manifold: Testing and Inspection Intake Manifold Vacuum Test Bring the engine to normal operating temperature. Connect the Vacuum/Pressure Tester to the intake manifold. Run the engine at the specified idle speed. The vacuum gauge should read between 51-74 kPa (15-22 in-Hg) depending upon the engine condition and the altitude at which the test is performed. Subtract 4.0193 kPa (1 in-Hg) from the specified reading for every 304.5 m (1,000 feet) of elevation above sea level. The reading should be steady. If necessary, adjust the gauge damper control (where used) if the needle is fluttering rapidly. Adjust the damper until the needle moves easily without excessive flutter. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Intake Manifold Vacuum Test > Page 2834 Intake Manifold: Testing and Inspection Interpreting Vacuum Gauge Readings A careful study of the vacuum gauge reading while the engine is idling will help pinpoint trouble areas. Always conduct other appropriate tests before arriving at a final diagnostic decision. Vacuum gauge readings, although helpful, must be interpreted carefully. Most vacuum gauges have a normal band indicated on the gauge face. Vacuum Gauge Readings The following are potential gauge readings. Some are normal; others should be investigated further. 1. NORMAL READING: Needle between 51-74 kPa (15-22 in-Hg) and holding steady. 2. NORMAL READING DURING RAPID ACCELERATION AND DECELERATION: When the engine is rapidly accelerated (dotted needle), the needle will drop to a low reading (not to zero). When the throttle is suddenly released, the needle will snap back up to a higher than normal figure. 3. NORMAL FOR HIGH-LIFT CAMSHAFT WITH LARGE OVERLAP: The needle will register as low as 51 kPa (15 in-Hg) but will be relatively steady. Some oscillation is normal. 4. WORN RINGS OR DILUTED OIL: When the engine is accelerated (dotted needle), the needle drops to 0 kPa (0 in-Hg). Upon deceleration, the needle runs slightly above 74 kPa (22 in-Hg). 5. STICKING VALVES: When the needle (dotted) remains steady at a normal vacuum but occasionally flicks (sharp, fast movement) down and back about 13 kPa (4 in-Hg), one or more valves may be sticking. 6. BURNED OR WARPED VALVES: A regular, evenly-spaced, downscale flicking of the needle indicates one or more burned or warped valves. Insufficient hydraulic lash adjuster or Hydraulic Lash Adjuster (HLA) clearance will also cause this reaction. 7. POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves are not seating. 8. WORN VALVE GUIDES: When the needle oscillates over about a 13 kPa (4 in-Hg) range at idle speed, the valve guides could be worn. As engine speed increases, the needle will become steady if guides are responsible. 9. WEAK VALVE SPRINGS: When the needle oscillation becomes more violent as engine rpm is increased, weak valve springs are indicated. The reading at idle could be relatively steady. 10. LATE VALVE TIMING: A steady but low reading could be caused by late valve timing. 11. IGNITION TIMING RETARDING: Retarded ignition timing will produce a steady but somewhat low reading. 12. INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small pulsation of the needle can occur. 13. INTAKE LEAK: A low, steady reading can be caused by an intake manifold or throttle body gasket leak. 14. BLOWN HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket or warped cylinder head-to-cylinder block surface 15. RESTRICTED EXHAUST SYSTEM: When the engine is first started and is idled, the reading may be normal, but as the engine rpm is increased, the back pressure caused by a clogged muffler, kinked tail pipe or other concerns will cause the needle to slowly drop to 0 kPa (0 in-Hg). The needle then may slowly rise. Excessive exhaust clogging will cause the needle to drop to a low point even if the engine is only idling. When vacuum leaks are indicated, search out and correct the cause. Excess air leaking into the system will upset the fuel mixture and cause Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Intake Manifold Vacuum Test > Page 2835 concerns such as rough idle, missing on acceleration or burned valves. If the leak exists in an accessory unit such as the power brake booster, the unit will not function correctly. Always fix vacuum leaks. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Page 2836 Intake Manifold: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 1. Disconnect the battery ground cable. 2. Drain the coolant system. 3. Compress and slide the hose clamp and disconnect the water outlet hose. 4. Remove the engine vacuum harness. Disconnect the harness as shown. 5. Remove the throttle body. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Page 2837 6. Disconnect the exhaust gas recirculation (EGR) valve to exhaust manifold tube lower fitting. 7. Disconnect the five RH fuel injector electrical connectors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Page 2838 8. Disconnect the five LH fuel injector electrical connectors. 9. Disconnect the water temperature indicator sender unit electrical connectors. 10. Disconnect and remove the ten coil and plug boots. 11. Remove the drive belt. 12. Remove the generator (GEN). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Page 2839 13. Disconnect the hose clamps and remove the heater water hose. 14. Remove the water thermostat. 15. Remove the two studs retaining the heater water return tube. 16. Remove the upper intake manifold bolts, the upper intake manifold and the intake manifold gaskets. Discard the intake manifold gaskets. 17. Pull back and remove the heater water return tube. Inspect the O-rings and replace if required. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Page 2840 18. Separate the upper and lower intake manifolds. ^ Remove the ten lower intake manifold bolts. ^ Discard the lower intake manifold to upper intake manifold gasket. 19. Clean all mating surfaces. INSTALLATION 1. Position the lower intake manifold gasket and the upper intake manifold on the lower intake manifold and loosely install the ten upper intake manifold bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Page 2841 2. Tighten the intake manifold bolts in the sequence shown. ^ Stage 1: 2 Nm (18 in. lbs.) ^ Stage 2: 8-12 Nm (71-106 in. lbs.) NOTE: Tighten the intake manifold bolts in two stages. 3. Position the water return tube as shown. 4. Install the heater water return tube studs. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Page 2842 5. Install the upper intake manifold. ^ Position the upper intake manifold gaskets and the intake manifold, and loosely install the bolts. 6. Tighten the intake manifold bolts in the sequence shown. ^ Stage 1: 2 Nm (18 in. lbs.) ^ Stage 2: 20-30 Nm (15-22 ft. lbs.) NOTE: Be sure to tighten the intake manifold bolts in two stages. 7. Install the thermostat. 8. Install the throttle body. Leave the engine cover off. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Page 2843 9. Install the heater water hose and position the clamp. 10. Connect the water temperature indicator sending unit electrical connector. 11. Install the generator. 12. Install the drive belt. 13. Install the coil and plug boots. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Page 2844 14. Connect the five LH fuel injector electrical connectors. 15. Connect the five RH fuel injector electrical connectors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Page 2845 16. Connect the engine emission vacuum harness. 1. EGR Valve 2. EGR Vacuum Regulator Solenoid 3. Vacuum Source 4. Fuel Pressure Regulator 17. Connect the EGR valve to exhaust manifold tube lower fitting. 18. Connect the fuel lines. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Page 2846 19. Connect the engine water outlet hose and position the hose clamp. 20. Install the air cleaner outlet tube. 21. Fill the cooling system. 22. Install the engine cover. 23. Reconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection For Testing of this and other gauges, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Panel, Testing and Inspection. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications Crankshaft Main Bearing Seal: Specifications TORQUE SPECIFICATIONS Rear Oil Seal Bolts .............................................................................................................................. ................................... 8-12 Nm (71-106 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal and Installation Crankshaft Main Bearing Seal: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. 2. Remove the flywheel. NOTE: It is not necessary to remove the transmission from the jack. 3. Use the Rear Crankshaft Slinger Remover and the Slide Hammer to remove the crankshaft oil slinger. 4. Use the Rear Crankshaft Seal Remover and the Impact Slide Hammer to remove the crankshaft rear oil seal. INSTALLATION 1. Clean and inspect the mating surface. CAUTION: Do not use metal scrapers wire brushes, power abrasive discs or other abrasive means to clean the aluminum retain plate. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. 2. Using the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter, install the crankshaft rear oil seal. 3. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer and the Rear Crankshaft Seal Replaces install the rear main seal slinger. 4. Install the flywheel. 5. Connect the battery ground cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal and Installation > Page 2857 Crankshaft Main Bearing Seal: Service and Repair With Retainer Plate REMOVAL 1. Disconnect the battery ground cable. 2. Remove the flywheel. NOTE: It is not necessary to remove the transmission from the jack. 3. Use the Rear Crankshaft Slinger Remover and the Impact Slide Hammer to remove the crankshaft oil slinger. 4. Use the Rear Crankshaft Seal Remover and the Impact Slide Hammer to remove the crankshaft rear oil seal. 5. Remove the oil pan. 6. Remove the crankcase bolts and the crankshaft rear oil seal retainer plate. INSTALLATION 1. Clean and inspect the mating surface. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal and Installation > Page 2858 2. Apply a bead of silicone around the rear oil seal retainer sealing surface. - Use Silicone Gasket and Sealant F6AZ-19562-A or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A. 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. 3. Position the crankshaft rear oil seal and retainer, install the bolts. Then install the oil pan and the two bolts. Tighten in two stages. - Stage 1: Tighten retainer plate bolts to 8-12 Nm (71-107 inch lbs.) - Stage 2: Tighten oil pan bolts to 14-20 Nm (10-15 ft. lbs.) then tighten an additional 90°. NOTE: If the rear main oil seal is still in place and being reinstalled, be sure the lip is not folded over or wrinkled during the retainer plate installation. The seal lip must start squarely on the crankshaft journal. 4. Use the Rear Crankshaft Seal Replacer and Rear Crankshaft Seal Adapter to install the crankshaft rear oil seal. 5. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer and Rear Crankshaft Seal Replacer to install the crankshaft oil slinger. 6. Install the flywheel. 7. Connect the battery ground cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2859 Crankshaft Main Bearing Seal: Tools and Equipment Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2860 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification Cylinder Head Gasket: Technical Service Bulletins Engine - Reman Engine Head Gasket Identification TSB 06-18-16 09/18/06 IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN REMANUFACTURED ENGINES - SERVICE TIP FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005 Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred, Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003 Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53 Motorhome Chassis LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004 Navigator, Navigator 2003-2004 Aviator 2006 Mark LT MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005 Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured engines, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket. ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for originally equipment level thickness head gasket) or OVR (for oversized service level thicker head gasket) remanufactured engine when replacing a head gasket. SERVICE PROCEDURE Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck, milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this additional information is available. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 2865 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 2866 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 2867 For certain remanufactured engines, the long block assembly will be uniquely identified with a build date, reman code, service part number, and serial number. This metal tag will be marked with STD, or with OVR (Figures 1-6). WARRANTY STATUS: Information Only Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 2868 Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 2869 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 2870 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 REMOVAL 1. Remove the crankshaft pulley. 2. Using the (a) Front Cover Seal Remover, remove the (B) crankshaft front seal. INSTALLATION 1. Lubricate the (A) engine timing cover and the (B) crankshaft front seal inner lip. 1 Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 2. Use the (A) Crankshaft Seal Replacer to install the (B) crankshaft front seal into the (C) engine timing cover. 3. Install crankshaft pulley. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2874 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Testing and Inspection Valve Guide Seal: Testing and Inspection The cylinder leakage detector tests for engine oil leaks and checks the valve stem seals for leakage. 1. Plug all crankcase openings except the one used for connecting the leakage detector. 2. Connect the Engine Cylinder Leak Detection/Air Pressurization Kit to a crankcase opening (an oil level indicator tube is convenient). Adjust the air pressure to approximately 34 kPa (5 psi). 3. Using a solution of liquid soap and water, brush the solution along the gasket sealing surfaces and bearing seals. Look for bubbles or foam. 4. Remove the spark plugs and rotate the crankshaft slowly with a wrench. Check for large amounts of air escaping into the cylinders as each intake valve and exhaust valve opens. 5. The spark plugs on the leaking cylinders will probably show deposits of burned oil. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Specifications Balance Shaft: Specifications GENERAL SPECIFICATIONS Balance Shaft Journal Diameter ........................................................................................................................................................... 26.962-26.936 mm Clearance-Balance Shaft Journal to Cylinder Head ................................................................................................................................. 0.076-0.025 mm Cylinder Head B/S Journal Diameter ................................................................................................................................................... 27.012-26.987 mm Gear Backlash ...................................................................................................... ................................................................................ 0.0076-0.1295 mm Balance Shaft Endplay ........ .............................................................................................................................................................. ........... 0.04-0.18 mm Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications TORQUE SPECIFICATIONS Camshaft Sprocket Bolts ............................................................................................................................................................ 55-75 Nm (41-55 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Testing and Inspection > Gears Camshaft Gear/Sprocket: Testing and Inspection Gears 1. Inspect the (A) camshaft thrust plate, the (B) cam gear and the (C) crank gear. - Replace as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Testing and Inspection > Gears > Page 2887 Camshaft Gear/Sprocket: Testing and Inspection Sprockets 1. Inspect the (A) timing chain/belt and the (B) sprockets. - Replace as necessary. WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHICLE, DO NOT OPERATE THE ENGINE WITH THE HOOD OPEN UNTIL THE FAN BLADE HAS BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION. NOTE: Specifications show the expected minimum or maximum condition. - If a component fails to meet the specifications, it is necessary to replace or refinish. If the component can be refinished, wear limits are provided as an aid to making a decision. Any component that fails to meet specifications and cannot be refinished must be replaced. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Testing and Inspection > Gears Crankshaft Gear/Sprocket: Testing and Inspection Gears 1. Inspect the (A) camshaft thrust plate, the (B) cam gear and the (C) crank gear. - Replace as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Testing and Inspection > Gears > Page 2892 Crankshaft Gear/Sprocket: Testing and Inspection Sprockets 1. Inspect the (A) timing chain/belt and the (B) sprockets. - Replace as necessary. WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHICLE, DO NOT OPERATE THE ENGINE WITH THE HOOD OPEN UNTIL THE FAN BLADE HAS BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION. NOTE: Specifications show the expected minimum or maximum condition. - If a component fails to meet the specifications, it is necessary to replace or refinish. If the component can be refinished, wear limits are provided as an aid to making a decision. Any component that fails to meet specifications and cannot be refinished must be replaced. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal Timing Chain: Service and Repair Removal Special Tools 1. Remove the engine timing cover. 2. Remove the crankshaft sensor ring from the crankshaft. 3. Remove the six bolts and remove the balance shaft bearing caps. 4. Remove the balance shaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 2897 5. Use the Crankshaft Holding Tool to position the crankshaft as shown. CAUTION: Unless otherwise instructed, at no time when the timing chain/belts are removed and the cylinder heads are installed may the crankshaft or camshaft be rotated. Severe piston and valve damage will occur. 6. Install the Camshaft Holding Tools on the camshafts. 7. Remove the bolts and the timing chain tensioners. Remove the timing chain tensioner arms from the dowel pins. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 2898 8. Remove the LH and RH timing chain/belts and the crankshaft sprockets 1 Remove the RH timing chain/belt from the camshaft sprocket. 2 Remove the RH timing chain/belt and outer crankshaft sprocket from the crankshaft. 3 Repeat for the LH timing chain/belt and crankshaft sprocket. 9. Remove the timing timing chain guides. - Remove the bolts. - Remove the timing chain guides. 10. N0TE: Romeo engine shown; Winsor engine similar. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 2899 On engines with bolt-on sprokets, remove the camshaft sproket. 1. Remove the bolt. 2. Remove the camshaft sproket. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 2900 Timing Chain: Service and Repair Installation 1. Compress the tensioner plunger, using an edge of a vise. CAUTION: Do not compress the cachet assembly. This will damage the rachet assembly. 2. Using a small screwdriver or pick, push back and hold the ratchet mechanism. 3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing. 4. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 2901 5. If copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks. 6. On engines equipped with bolt-on sprockets, install the camshaft sprocket (2). 1 Install the bolt (1). 2 Tighten the bolt. ^ M10 bolt: Tighten in two stages. ^ Stage 1: Tighten to 40 Nm (30 ft. lbs.). ^ Stage 2: Tighten an additional 90°. ^ M12 bolt: Tighten to 120 Nm (90 ft. lbs.). 7. Install the timing chain guides. 8. Position the crankshaft with the Crankshaft Holding Tool, and remove the tool. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 2902 9. Install the inner crankshaft sprocket with the long hub facing outward. 10. Install the inner timing chain/belt on the crankshaft sprocket with the timing marks aligned. 11. Install the timing chain/belt on the camshaft sprocket with the two chain links and timing marks aligned. NOTE: Be sure the upper half of the timing chain/belt is below the tensioner guide dowel. If necessary, use the Camshaft Positioning Tool to adjust. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 2903 12. Install the outer crankshaft sprocket and timing chain/belt with the long hub of the crankshaft sprocket facing inward. CAUTION: The camshaft sprocket can jump time if the Camshaft Holding Tool is not secured. NOTE: Be sure the chain link and crankshaft sprocket timing marks are aligned. - The lower half of the timing chain/belt must be positioned above the dowel. 13. Position the timing chain/belt on the camshaft sprocket. Make sure the two copper-colored links align with the camshaft sprocket timing mark. 14. Check for proper alignment of all timing marks. 15. Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioners and install the bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 2904 16. Remove the retaining pins from the RH and LH timing chain tensioners 17. Remove the Camshaft Holding Tools from the camshafts. 18. Install the crankshaft sensor ring on the crankshaft. 19. Lubricate the balance shaft journals with engine oil. - Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G 20. Position the balance shaft on the journals. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 2905 21. Align the balance shaft timing marks as shown. 22. Install the bearing caps, the bolts and tighten the bolts in the sequence shown. 23. Apply a bead of silicone along the cylinder head-to-block surface and the oil pan-to-block surface. - Use Silicone Gasket and Sealant F6AZ-19562-A or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: The timing chain/belt is removed for clarity. - If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with solvent. 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. 24. Install engine timing cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications Timing Chain Guide: Specifications TORQUE SPECIFICATIONS Timing Chain Guide Bolts ...................................................................................................................................................... 8-12 Nm (71-106 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Service and Repair > Removal Timing Chain Guide: Service and Repair Removal 1. Remove the engine timing cover. 2. Remove the crankshaft sensor ring from the crankshaft. 3. Remove the six bolts and remove the balance shaft bearing caps. 4. Remove the balance shaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Service and Repair > Removal > Page 2911 5. Use the Crankshaft Holding Tool to position the crankshaft as shown. CAUTION: Unless otherwise instructed, at no time when the timing chain/belts are removed and the cylinder heads are installed may the crankshaft or camshaft be rotated. Severe piston and valve damage will occur. 6. Install the Camshaft Holding Tools on the camshafts. 7. Remove the bolts and the timing chain tensioners. Remove the timing chain tensioner arms from the dowel pins. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Service and Repair > Removal > Page 2912 8. Remove the LH and RH timing chain/belts and the crankshaft sprockets 1 Remove the RH timing chain/belt from the camshaft sprocket. 2 Remove the RH timing chain/belt and outer crankshaft sprocket from the crankshaft. 3 Repeat for the LH timing chain/belt and crankshaft sprocket. 9. Remove the timing timing chain guides. - Remove the bolts. - Remove the timing chain guides. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Service and Repair > Removal > Page 2913 Timing Chain Guide: Service and Repair Installation 1. Compress the tensioner plunger, using an edge of a vise. CAUTION: Do not compress the cachet assembly. This will damage the rachet assembly. 2. Using a small screwdriver or pick, push back and hold the ratchet mechanism. 3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing. 4. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Service and Repair > Removal > Page 2914 5. If copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks. 6. Install the timing chain guides. 7. Position the crankshaft with the Crankshaft Holding Tool, and remove the tool. 8. Install the inner crankshaft sprocket with the long hub facing outward. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Service and Repair > Removal > Page 2915 9. Install the inner timing chain/belt on the crankshaft sprocket with the timing marks aligned. 10. Install the timing chain/belt on the camshaft sprocket with the two chain links and timing marks aligned. NOTE: Be sure the upper half of the timing chain/belt is below the tensioner guide dowel. If necessary, use the Camshaft Positioning Tool to adjust. 11. Install the outer crankshaft sprocket and timing chain/belt with the long hub of the crankshaft sprocket facing inward. CAUTION: The camshaft sprocket can jump time if the Camshaft Holding Tool is not secured. NOTE: Be sure the chain link and crankshaft sprocket timing marks are aligned. - The lower half of the timing chain/belt must be positioned above the dowel. 12. Position the timing chain/belt on the camshaft sprocket. Make sure the two copper-colored links align with the camshaft sprocket timing mark. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Service and Repair > Removal > Page 2916 13. Check for proper alignment of all timing marks. 14. Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioners and install the bolts. 15. Remove the retaining pins from the RH and LH timing chain tensioners 16. Remove the Camshaft Holding Tools from the camshafts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Service and Repair > Removal > Page 2917 17. Install the crankshaft sensor ring on the crankshaft. 18. Lubricate the balance shaft journals with engine oil. - Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G 19. Position the balance shaft on the journals. 20. Align the balance shaft timing marks as shown. 21. Install the bearing caps, the bolts and tighten the bolts in the sequence shown. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Service and Repair > Removal > Page 2918 22. Apply a bead of silicone along the cylinder head-to-block surface and the oil pan-to-block surface. - Use Silicone Gasket and Sealant F6AZ-19562-A or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: The timing chain/belt is removed for clarity. - If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with solvent. 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. 23. Install engine timing cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Removal Timing Chain Tensioner: Service and Repair Removal 1. Remove the engine timing cover. 2. Remove the crankshaft sensor ring from the crankshaft. 3. Remove the six bolts and remove the balance shaft bearing caps. 4. Remove the balance shaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Removal > Page 2923 5. Use the Crankshaft Holding Tool to position the crankshaft as shown. CAUTION: Unless otherwise instructed, at no time when the timing chain/belts are removed and the cylinder heads are installed may the crankshaft or camshaft be rotated. Severe piston and valve damage will occur. 6. Install the Camshaft Holding Tools on the camshafts. 7. Remove the bolts and the timing chain tensioners. Remove the timing chain tensioner arms from the dowel pins. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Removal > Page 2924 8. Remove the LH and RH timing chain/belts and the crankshaft sprockets 1 Remove the RH timing chain/belt from the camshaft sprocket. 2 Remove the RH timing chain/belt and outer crankshaft sprocket from the crankshaft. 3 Repeat for the LH timing chain/belt and crankshaft sprocket. 9. Remove the timing timing chain guides. - Remove the bolts. - Remove the timing chain guides. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Removal > Page 2925 Timing Chain Tensioner: Service and Repair Installation 1. Compress the tensioner plunger, using an edge of a vise. CAUTION: Do not compress the cachet assembly. This will damage the rachet assembly. 2. Using a small screwdriver or pick, push back and hold the ratchet mechanism. 3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing. 4. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Removal > Page 2926 5. If copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks. 6. Install the timing chain guides. 7. Position the crankshaft with the Crankshaft Holding Tool, and remove the tool. 8. Install the inner crankshaft sprocket with the long hub facing outward. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Removal > Page 2927 9. Install the inner timing chain/belt on the crankshaft sprocket with the timing marks aligned. 10. Install the timing chain/belt on the camshaft sprocket with the two chain links and timing marks aligned. NOTE: Be sure the upper half of the timing chain/belt is below the tensioner guide dowel. If necessary, use the Camshaft Positioning Tool to adjust. 11. Install the outer crankshaft sprocket and timing chain/belt with the long hub of the crankshaft sprocket facing inward. CAUTION: The camshaft sprocket can jump time if the Camshaft Holding Tool is not secured. NOTE: Be sure the chain link and crankshaft sprocket timing marks are aligned. - The lower half of the timing chain/belt must be positioned above the dowel. 12. Position the timing chain/belt on the camshaft sprocket. Make sure the two copper-colored links align with the camshaft sprocket timing mark. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Removal > Page 2928 13. Check for proper alignment of all timing marks. 14. Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioners and install the bolts. 15. Remove the retaining pins from the RH and LH timing chain tensioners 16. Remove the Camshaft Holding Tools from the camshafts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Removal > Page 2929 17. Install the crankshaft sensor ring on the crankshaft. 18. Lubricate the balance shaft journals with engine oil. - Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G 19. Position the balance shaft on the journals. 20. Align the balance shaft timing marks as shown. 21. Install the bearing caps, the bolts and tighten the bolts in the sequence shown. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Removal > Page 2930 22. Apply a bead of silicone along the cylinder head-to-block surface and the oil pan-to-block surface. - Use Silicone Gasket and Sealant F6AZ-19562-A or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: The timing chain/belt is removed for clarity. - If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with solvent. 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. 23. Install engine timing cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal Timing Cover: Service and Repair Removal WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 1. Disconnect the battery ground cable 2. Remove the valve covers. 3. Remove the radiator. 4. Disconnect the Camshaft Position Sensor (CMP sensor). 5. Remove the water pump. 6. Raise and support the vehicle. 7. Remove the bolts and position the power steering pump aside. NOTE: Only three bolts are required to secure the power steering pump. 8. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 9. Remove the drain plug and drain the engine oil. 10. Remove the crankshaft front seal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2935 11. Remove the bolts. 12. Lower the vehicle. 13. Remove the engine timing cover fasteners. 14. Remove the engine timing cover from the front cover to cylinder block dowels. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2936 Timing Cover: Service and Repair Installation 1. Install a new engine timing cover gasket on the engine timing cover, then position the engine timing cover on the front cover to cylinder block dowels. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2937 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2938 2. Loosely install the cover fasteners. 3. Tighten the fasteners in two stages following the sequence shown. - Stage 1: Tighten fasteners 1 through 5 to 20-30 Nm (15-22 ft. lbs.) - Stage 2: Tighten fasteners 6 through 15 to 40-55 Nm (30-41 ft. lbs.) 4. Tighten the bolts in the sequence shown. - Stage 1: Tighten to 20 Nm (15 ft. lbs.) - Stage 2: Tighten an additional 60 degrees NOTE: Be sure to tighten the bolts in two stages. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2939 5. Connect the CKP sensor electrical connector. 6. Install the bolts. 7. Lower the vehicle. 8. Install the water pump. 9. Connect the CMP electrical connector. 10. Raise and support the vehicle. 11. Install a new crankshaft front seal and the crankshaft pulley. 12. Lower the vehicle. 13. Install the valve covers. 14. Install the radiator and fill the cooling system. 15. Install the engine Air Cleaner (ACL) and the air cleaner outlet tube. 16. Connect the battery ground cable. 17. Fill the engine with oil. - Use engine oil meeting Ford specification WSS-M2C153-G. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service and Repair Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. - BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. 1. Perform the pre-service procedures. 2. Disconnect the battery ground cable. 3. Remove the (B) fuel pressure relief valve from the (A) fuel injection supply manifold. INSTALLATION 1. Install the fuel pressure relief valve and tighten. 2. Connect the battery ground cable. 3. Perform the post-service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Automatic Transmission Idle Speed: Specifications With Automatic Transmission Hot Idle ................................................................................................................................................ ......................................................... 780 - 810 RPM Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Automatic Transmission > Page 2949 Idle Speed: Specifications With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 780 - 810 RPM Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 REMOVAL 1. Lift the engine air cleaner inlet tube and remove. 2. Unlatch the clamp and remove the air cleaner tray. 3. Remove the air cleaner element. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 EFI/CFI Fuel Pressure Gauge WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the fuel pressure gauge. 2. Slowly open the manual valve on the fuel pressure gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place fuel in a suitable container. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order: 1-6-5-10-2-7-3-8-4-9 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark Plug Gap ................................................................................................................................... ................................... 1.32-1.42 mm (0.052-0.056 in) Spark Plug Torque ......................................... ....................................................................................................................................... 9-20 Nm (7-14 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 2969 Spark Plug: Specifications Torque Spark Plug Gap ................................................................................................................................... ................................... 1.32-1.42 mm (0.052-0.056 in) Spark Plug Torque ......................................... ....................................................................................................................................... 9-20 Nm (7-14 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2970 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................ AWSF22E Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2971 Spark Plug: Service and Repair REMOVAL CAUTION: Mark spark plug locations and return to original location. 1. Remove the ignition coil. 2. Remove the spark plug. 3. Inspect the spark plugs; replace if required. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test Compression Check: Testing and Inspection Compression Test 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly 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 five 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. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test > Page 2977 Compression Check: Testing and Inspection Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating improperly. 3. If two 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 percent of the highest reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test > Page 2978 Compression Check: Testing and Inspection Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification WSS-M2C153-F on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications TORQUE SPECIFICATIONS Water Pump Pulley Mounting Bolts .......................................................................................................................................... 20-30 Nm (15-22 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity 30.6 qts .............................................................................................................................................................. ....................................... Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2991 Coolant: Fluid Type Specifications COOLANT TYPE Ethylene Glycol (EC) .............................................................................................................................................................. ........... Coolant Mixture with Water 50% .............................................................................................................................................................. ........................ Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolant type. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications TORQUE SPECIFICATIONS Cylinder Drain Plug .............................................................................................................................. ..................................... 16-24 Nm (12-18 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications Fan Blade: Specifications TORQUE SPECIFICATIONS Fan Blades to Fan Clutch Mounting Bolts .............................................................................................................................. 17-23 Nm (12.5-17 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 2999 Fan Blade: Service and Repair REMOVAL 1. Drain the cooling system. 2. Remove the air cleaner assembly. 3. Remove the plastic rivet retainers and the air deflector. 4. Remove the radiator hoses from the radiator. 5. Disconnect the overflow hose from the radiator. 6. Remove the (A) fan and fan clutch from the (B) water pump pulley. CAUTION: The large clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it. 7. Remove the (A) bolts and lift the (B) fan shroud, fan and fan clutch from the vehicle. 8. Remove the underbody splash shield, if so equipped. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 3000 9. Compress the (A) clamps and slide away from the (B) radiator Twist the (C) transmission oil cooler hoses and remove from the radiator. 10. Remove the (A) bolts retaining the (B) support brackets to the (C) radiator support. Lift the radiator support brackets upwards and away from the (D) radiator. 11. Remove the radiator from the vehicle. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 3001 1. Follow the removal procedure in reverse order. 2. Install hose clamps where the shrink clamps were removed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Operational Test Fan Clutch: Testing and Inspection Fan Clutch Operational Test 1. Spin the fan blade by hand. A light resistance should be felt. If there is no resistance or very high resistance, the minimum and maximum fan speeds must be checked as follows: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Operational Test > Page 3006 Fan Clutch: Testing and Inspection Maximum Speed Fan Clutch Requirement Test 1. Perform Steps l through 5 of the Fan Clutch Test-Minimum Speed Requirement. 2. Block off areas on each side of the radiator in the engine compartment and the front of the radiator grille. This will raise the temperature of the air striking the fan clutch and should cause the fan blade to operate at maximum speed. NOTE: The temperature should be above 96°C (205°F) for maximum fan speed. 3. Place the climate control function selector switch in the MAX A/C position and the blower motor switch in the HI position. 4. Adjust the strobe to 3000 rpm. 5. Start the engine and adjust the engine speed until the strobe light flash and the water pump pulley mark are synchronized. WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHICLE, DO NOT OPERATE THE ENGINE UNTIL THE FAN BLADE HAS BEEN FIRST EXAMINED FOR POSSIBLE CRACKS AND SEPARATION. 6. Aim the strobe light at the fan blade retaining bolts. Adjust the strobe light until the light flash is synchronized with the marked fan blade bolt (the fan blade appears to stand still). 7. If the fan blade speed is less than 2300 rpm, replace the fan clutch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Operational Test > Page 3007 Fan Clutch: Testing and Inspection Minimum Speed Fan Clutch Requirement Test 1. Use a suitable marker to mark the water pump pulley, one of the fan blade retaining bolts and the crankshaft pulley. 2. Connect a tachometer to the engine. 3. Install a throttle adjusting tool. 4. Connect the Digital Photoelectric Tachometer. 5. Start the engine and run it at approximately 1500 rpm until the normal operating temperature has been achieved. WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHICLE, DO NOT OPERATE THE ENGINE UNTIL THE FAN BLADE HAS BEEN FIRST EXAMINED FOR POSSIBLE CRACKS AND SEPARATION. 6. Adjust the engine speed to 2300 rpm. 7. Operate the strobe light at 3000 rpm and aim it at the water pump pulley. Adjust the engine speed until the light flash and the water pump pulley mark are synchronized. 8. Aim the strobe light at the fan blade bolts. Adjust the strobe light until the light flash is synchronized with the marked fan blade bolt (the fan blade appears to stand still). 9. The fan blade speed must not be greater than 1500 rpm at 3000 water pump rpm. 10. Turn the engine off. 11. If the fan blade speed was greater than 1500 rpm, replace the fen crutch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Page 3008 Fan Clutch: Service and Repair TORQUE SPECIFICATIONS Fan Clutch Hub to Water Pump ........................................................................................................................................... 113-153 Nm (83-117 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Page 3009 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 Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3014 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3015 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Partially drain the cooling system. 3. Remove the Engine Coolant Temperature sensor (ECT sensor). 1. Disconnect the electrical connector. 2. Remove the ECT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Engine Temperature Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 3019 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 3020 Engine Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Generator (GEN). 3. Remove cylinder head temperature sensor. 1. Disconnect the electrical connector. 2. Remove the CHT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications TORQUE SPECIFICATIONS Water Temperature Indicator Sender Unit ................................................................................................................................. 16-24 Nm (12-18 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3024 Temperature Sensor (Gauge): Locations Engine Views The Instrumentation Engine Coolant Temperature Sensor is located on the upper left front of engine. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3025 Temperature Sensor (Gauge): Service and Repair REMOVAL 1. Remove the air cleaner assembly. 2. Partially drain the cooling system. 3. Disconnect the electrical connector. Remove the engine coolant temperature sensor from the intake manifold. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications TORQUE SPECIFICATIONS Fan Shroud Mounting Bolts ........................................................................................................................................................ 5-7 Nm (44-62 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications > Page 3029 Fan Shroud: Service and Repair REMOVAL 1. Drain the cooling system. 2. Remove the air cleaner assembly. 3. Remove the plastic rivet retainers and the air deflector. 4. Remove the radiator hoses from the radiator. 5. Disconnect the overflow hose from the radiator. 6. Remove the (A) fan and fan clutch from the (B) water pump pulley. CAUTION: The large clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it. 7. Remove the (A) bolts and lift the (B) fan shroud, fan and fan clutch from the vehicle. 8. Remove the underbody splash shield, if so equipped. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications > Page 3030 9. Compress the (A) clamps and slide away from the (B) radiator Twist the (C) transmission oil cooler hoses and remove from the radiator. 10. Remove the (A) bolts retaining the (B) support brackets to the (C) radiator support. Lift the radiator support brackets upwards and away from the (D) radiator. 11. Remove the radiator from the vehicle. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications > Page 3031 1. Follow the removal procedure in reverse order. 2. Install hose clamps where the shrink clamps were removed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3040 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3041 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3047 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3048 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Auxiliary Heater Core: Description and Operation Auxiliary The auxiliary A/C system uses a rear-mounted heater core which operates in the same manner as the front mounted heated core. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Auxiliary > Page 3051 Heater Core: Description and Operation Heating and Defrosting Heater Core The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 3052 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. 1. 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. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require replacement. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Perform a system inspection by checking the heater system thoroughly as follows: 2. Check the integrity of the heater water hose clamps. 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. Heater Core-Plugged WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the proper level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot: If it is not hot: the heater core may have an air pocket - the heater core may be plugged - the thermostat is not working properly. Heater Core-Pressure Test Use the Radiator/Heater Core Pressure Tester to perform the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) 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 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three 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 perform the bench test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 3053 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 inch) 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 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, replace the heater core. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core Heater Core: Service and Repair Back Flushing-Heater Core 1. Once pressure is released, remove the pressure relief cap. WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DAMAGE TO THE COOLING SYSTEM ENGINE OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMOVING THE PRESSURE RELIEF CAP, WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE PRESSURE RELIEF CAP AND TURN IT SLOWLY. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN RELEASED, (STILL WITH A CLOTH) TURN AND REMOVE THE PRESSURE RELIEF CAP. 2. Partially drain the cooling system. 3. Use cooling system Flush-ALL Flush Kit Hardware Package and Drain Kit to backflush the hater core. Use Ford Premium Cooling System Flush F1AZ-19A503-A meeting Ford specification ESR-M14P7A. NOTE: Refer to the cooling system Flush-ALL Operating Instructions for particular vehicle hook-up. 4. Fill the cooling system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 3056 Heater Core: Service and Repair Heating and Defrosting REMOVAL 1. Drain the engine cooling system. 2. Disconnect the battery ground cable. 3. Disconnect the quick disconnect heater hose couplings at the heater core. 4. Plug the heater water hoses with a suitable 5/8-inch or 3/4-inch plug. 5. Remove the engine cover. 6. Remove the instrument panel finish panel. 7. Remove the heater core cover. 1. Remove the seven screws. 2. Remove the heater core cover. - Remove and discard the heater core case seal. 8. Remove the heater core. NOTE: Use care not to spill the coolant remaining in the heater core during removal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 3057 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 3058 Heater Core: Service and Repair With Auxiliary Air Conditioning REMOVAL 1. If equipped, remove the third, fourth, and fifth bench seats as required. 2. If equipped, remove the trim panels. - Remove the left center bolster trim panel. - Remove the quarter trim rear upper panel. - Remove the lower rear body side trim panel. 3. Remove the heater core cover. 1. Remove the screws. 2. Remove the heater core cover. 4. Clamp off the heater water hoses. 5. Disconnect the heater water hoses. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 3059 6. Remove the heater core. 1. Remove the heater core case seal. 2. Remove the heater core. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Page 3060 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3069 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3070 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3076 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3077 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3078 Heater Hose: Description and Operation A/C Lines And Heater Tubes - Vehicle Underbody, Vans Except RV Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3079 A/C Lines And Heater Tubes - Vehicle Underbody, Vans And Cutaways The auxiliary A/C system uses a rear-mounted heater core which operates in the same manner as the front mounted heater core. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose Heater Hose: Service and Repair Auxillary Heater Hose A/C Lines And Heater Tubes - Vehicle Underbody, Vans Except RV Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose > Page 3082 A/C Lines And Heater Tubes - Vehicle Underbody, Vans And Cutaways OE provides no specific replacement procedure for these hoses. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose > Page 3083 Heater Hose: Service and Repair Heater Hose Couplings Heater Hose Disconnect Tool SPECIAL TOOL(S) DISCONNECT 1. Depressurize the engine cooling system. WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. Push the Heater Hose Disconnect Tool over the coupling retainer windows to compress the retainer locking tabs. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Tool must be perpendicular to and on the highest point of the coupling. 4. Pull the heater water hose away from the heater core tube. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose > Page 3084 7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer. CONNECT 1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. 2. Install a new coupling retainer, spacer, and lubricated O-rings into the quick disconnect coupling housing. 3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose > Page 3085 Heater Hose: Service and Repair Removal and Installation REMOVAL 1. Drain the cooling system. 2. Disconnect the quick disconnect heater hose couplings at the heater core. 3. Remove the engine cover. 4. Disconnect the supply heater water hose at the engine. 5. Disconnect the return heater water hose at the engine. 6. Disconnect the quick disconnect heater hose couplings from the heater water hoses. NOTE: This step must be performed if the vehicle is equipped with an auxiliary A/C-heater system. 7. Remove the heater water hoses. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose > Page 3086 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Page 3087 Heater Hose Disconnect Tool Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection For Testing of this and other gauges, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Panel, Testing and Inspection. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications Radiator: Specifications TORQUE SPECIFICATIONS Radiator Mounting Brackets Retaining Bolts ......................................................................................................................... 6-14 Nm (53-124 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 3095 Radiator: Testing and Inspection 1. Leak-test the radiator in clean water with 138 kPa (20 psi) air pressure. NOTE: Always install plugs in the oil cooler fittings before leak-testing or cleaning any radiator. - Clean the radiator before leak-testing to avoid contamination of tank. CAUTION: Never leak test an aluminum radiator in the same water that copper/brass radiators are tested in. Flux and caustic cleaners may be present in the cleaning tank and they will damage aluminum radiators. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 3096 Radiator: Service and Repair REMOVAL 1. Drain the cooling system. 2. Remove the air cleaner assembly. 3. Remove the plastic rivet retainers and the air deflector. 4. Remove the radiator hoses from the radiator. 5. Disconnect the overflow hose from the radiator. 6. Remove the (A) fan and fan clutch from the (B) water pump pulley. CAUTION: The large clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it. 7. Remove the (A) bolts and lift the (B) fan shroud, fan and fan clutch from the vehicle. 8. Remove the underbody splash shield, if so equipped. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 3097 9. Compress the (A) clamps and slide away from the (B) radiator Twist the (C) transmission oil cooler hoses and remove from the radiator. 10. Remove the (A) bolts retaining the (B) support brackets to the (C) radiator support. Lift the radiator support brackets upwards and away from the (D) radiator. 11. Remove the radiator from the vehicle. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 3098 1. Follow the removal procedure in reverse order. 2. Install hose clamps where the shrink clamps were removed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection Radiator Cap: Testing and Inspection WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE COOLING SYSTEM, USE EXTREME CARE WHEN REMOVING THE PRESSURE RELIEF CAP FROM A HOT DEGAS BOTTLE. WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE PRESSURE RELIEF CAP AND TURN IT SLOWLY ONE TURN (COUNTERCLOCKWISE). STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN CERTAIN ALL THE PRESSURE HAS BEEN RELEASED, REMOVE PRESSURE RELIEF CAP (STILL WITH A CLOTH) 1. Remove the pressure relief cap from the degas bottle. 2. Immerse the pressure relief cap in water and install it on the shallow filler neck of Radiator/Heater Core Pressure Tester and Radiator Cap Adapter, part of Radiator/Heater Core Pressure Tester. 3. Immerse the filler neck seal in water and install it in the filler neck adapter. 4. Install the filler neck adapter with the filler neck seal to the Radiator Cap Adapter. 5. Connect the female quick-connect fitting of the pressure test pump to the male quick-connect fitting of the filler neck adapter. 6. Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops increasing and note the highest pressure reading obtained. NOTE: If the plunger of the pump is depressed too fast, an erroneous pressure reading will result. 7. Release the pressure by turning the relief screw counterclockwise. Then tighten the pressure relief screw and repeat Step 6 (at least twice) to make sure the reading is repeatable within the specifications of the pressure relief cap. 8. If the pressure test gauge readings are not within specifications, replace the pressure relief cap. If the pressure test gauge readings are within specifications, perform the cooling system Pressure Test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3107 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3108 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Partially drain the cooling system. 3. Remove the Engine Coolant Temperature sensor (ECT sensor). 1. Disconnect the electrical connector. 2. Remove the ECT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Engine Temperature Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3112 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3113 Engine Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Generator (GEN). 3. Remove cylinder head temperature sensor. 1. Disconnect the electrical connector. 2. Remove the CHT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications TORQUE SPECIFICATIONS Water Temperature Indicator Sender Unit ................................................................................................................................. 16-24 Nm (12-18 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3117 Temperature Sensor (Gauge): Locations Engine Views The Instrumentation Engine Coolant Temperature Sensor is located on the upper left front of engine. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3118 Temperature Sensor (Gauge): Service and Repair REMOVAL 1. Remove the air cleaner assembly. 2. Partially drain the cooling system. 3. Disconnect the electrical connector. Remove the engine coolant temperature sensor from the intake manifold. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection For Testing of this and other gauges, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Panel, Testing and Inspection. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Temperature Initial .................................................................................................................................................... ............................................ 80-84°C (176-183°F) Fully Open ............................................................ ........................................................................................................................................ 95°C (203°F) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > Thermostat Test Thermostat: Testing and Inspection Thermostat Test 1. Remove the water thermostat. 2. Check the water thermostat for seating. Hold the water thermostat up to a lighted background. Leakage of light around the thermostat valve at room temperature indicates that the water thermostat should be replaced. Some water thermostats have a small leakage notch at one location on the perimeter of the thermostat valve, which is considered normal. 3. Immerse the water thermostat in a boiling antifreeze and water mixture. 4. See Specifications for water thermostat opening temperatures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > Thermostat Test > Page 3127 Thermostat: Testing and Inspection Electrical Thermostat Test CAUTION: Always vent the exhaust to the outside when performing this test. NOTE: The electrical thermostat test is most accurate if performed indoors at less than 37.8°C (100°F) ambient air. This test may be performed with or without the hood open and with the engine warm or cold. 1. Check the engine coolant level. Fill as needed. 2. With the ignition OFF, remove the Engine Coolant Temperature (ECT) sensor harness connector and attach ECT Sensor "T" Cable as a jumper between the Powertrain Control Module (PCM) and the ECT Sensor. Attach the 73 Digital Multimeter to the ECT Sensor "T" Cable. Voltage values (0-5 V) may now be monitored while the sensor retains its connection to the wiring harness. New Generation Star (NGS) Tester or the Service Bay Diagnostic System (SBDS) may be used to monitor the ECT on vehicles equipped with Data Link Connector (DLC). The SBDS sequence to use for the screen is: Toolbox-Electronic Engine Control and DCL-Item. 3. Place the transmission in PARK (P) or NEUTRAL (N) NOTE: Running this test with the vehicle in gear or with the A/C compressor clutch engaged (running) will cause improper diagnosis. 4. Start the engine and allow the engine to idle throughout this test. Allow the engine to run for 2 minutes, then record the ECT voltage. Record the ECT voltage every 60 seconds. When the ECT voltage trend changes direction or only changes slightly (0.03 voltage or less) from the previous reading, record this as the thermostat opening voltage. Use the voltage and corresponding coolant temperature chart listed below. 5. If the thermostat opening voltage is greater than 0.75 volts and less than 82°C (180°F), replace the water thermostat. 6. If the thermostat opening voltage is less than 0.75 volts and greater than 82°C (180°F), the water thermostat is good and should not be replaced. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications TORQUE SPECIFICATIONS Water Pump Pulley Mounting Bolts .......................................................................................................................................... 20-30 Nm (15-22 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: Customer Interest Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3142 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3143 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3149 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3150 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Warranty - Exhaust Manifolds Update Technical Service Bulletin # 98L20 Date: 981201 Warranty - Exhaust Manifolds Update 98L20 SPECIAL FIELD ACTION 1993 through 1995 California Passenger Cars and Light Trucks Equipped with 3.0/3.2L Engines and 1997 through 1999 California E-250/350 Econolines and F-Series Equipped with 6.8L Engines - Revised Warranty Information ^ Dealer Letter ^ Attachment I ^ Warranty Information ^ Labor Allowances ^ Reimbursement Information ^ Customer Notification Letter - Kit "A" 1993-1995 3.0L and 3.2L Engine Equipped Vehicle Owners ^ Customer Notification Letter - Kit "B" 1997-1999 6.8L Engine Equipped Vehicle Owners Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Warranty - Exhaust Manifolds Update > Page 3155 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Warranty - Exhaust Manifolds Update > Page 3156 Attachment I - Administrative Information WARRANTY INFORMATION PAGE ORDERING INFORMATION Revised warranty information pages for this program are being sent directly to owners of affected vehicles. In the event that customers return to your dealership requesting replacement pages, call the following phone number and ask for 98L20 pages. __ Call 1-800-325-5621 __ Order 98L20 Materials LABOR ALLOWANCE - OWNERS REQUESTING DEALER ASSISTANCE TO REPLACE PAGES REIMBURSEMENT FOR CUSTOMER OUT-OF-POCKET EXHAUST MANIFOLD REPLACEMENT See Section 3-62 of the ACESII manual. Enter using DWE Program Code - 98L20 Misc. Expense - REFUND Misc. Expense - ADMIN Misc. Expense - 0.2 Hrs. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Warranty - Exhaust Manifolds Update > Page 3157 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Warranty - Exhaust Manifolds Update > Page 3158 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Page 3159 Exhaust Manifold: Specifications TORQUE SPECIFICATIONS Exhaust Manifold Nuts: 23-27 Nm (17-20 ft. lbs.) Exhaust System to Exhaust Manifold Nuts: 34-46 Nm (27-34 ft. lbs.) LH Sequence RH Sequence Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Page 3160 Exhaust Manifold: Testing and Inspection 1. Place a Straightedge across the exhaust manifold flanges and check for warping with a feeler gauge. NOTE: The 4.6L exhaust manifold is shown; the 4.2L exhaust manifold is similar. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side Exhaust Manifold: Service and Repair Left Side REMOVAL 1. Raise and support the vehicle. 2. Disconnect the EGR-to-exhaust manifold tube lower fitting. 3. Remove the nuts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3163 4. Remove the exhaust manifold nuts and the exhaust manifold. Discard the exhaust manifold gaskets. 5. Clean and inspect the exhaust manifold. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3164 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3165 Exhaust Manifold: Service and Repair Right Side REMOVAL 1. Raise and support the vehicle. 2. Remove the nuts. 3. Remove the ten nuts and the exhaust manifold and exhaust manifold gasket. Discard the exhaust manifold gasket. 4. Clean and inspect the exhaust manifold. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3166 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications TORQUE SPECIFICATIONS Inlet Pipe to TWC Flange Nuts .................................................................................................................................................. 34-46 Nm (25-33 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise Heat Shield: Customer Interest Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 3178 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 3179 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Heat Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3185 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3186 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 3194 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Engine Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3199 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3200 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3201 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3202 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3203 Engine Control Module: Locations Engine Compartment Views The Powertrain Control Module is located at the left rear of the engine compartment, near brake master cylinder. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3206 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3207 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3208 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3209 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3210 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3211 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3212 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3213 Engine Control Module: Connector Views Powertrain Control Module (Part 1 Of 2) 6.8 L E350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3214 Powertrain Control Module (Part 2 Of 2) 6.8 L E350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Powertrain Control Modules (PCMs) are reprogrammable to update calibration levels without having to replace the PCM. The reprogramming may be performed with the PCM installed in the vehicle using the Service Bay Technical System (SBTS). The PCM may also be reprogrammed outside of the vehicle using the New Generation STAR (NGS) and a 15- to 104- Pin Flash Cable (007-00587 or equivalent). The Flash Cable connects between the NGS and the PCM. The proper calibration must be downloaded to the Data Transfer Card through the SBTS. Follow the download instructions displayed on the NGS screen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3217 Engine Control Module: Reset Procedure NOTE: All OBD II scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears oxygen sensor test data. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation STAR (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTC's. New Generation STAR and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. To reset Keep Alive Random Access Memory, disconnect the battery ground cable for a minimum of 5 minutes. Resetting Keep Alive RAM will clear learned values the PCM has stored for adaptive systems such as idle and fuel trim. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3218 Engine Control Module: Removal and Replacement REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly. 3. Remove the wiring harness retaining bolt and wiring connector cover. 4. Disconnect the wiring harness. 5. Remove the retaining nuts and the Powertrain Control Module (PCM). INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3222 Engine Compartment Fuse Box (Part 2 Of 2) The PCM Power Relay is located at LH front of engine compartment, in engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 3228 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3232 Engine Compartment Fuse Box (Part 1 Of 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3233 Engine Compartment Fuse Box (Part 2 Of 2) The Fuel Pump Relay is located in the LH front of engine compartment, in engine compartment fuse box Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3236 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3237 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3238 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3239 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3240 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3241 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3242 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3246 Engine Compartment Fuse Box (Part 2 Of 2) The PCM Power Relay is located at LH front of engine compartment, in engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3257 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3258 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3264 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3265 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3271 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3272 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3278 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3279 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3280 Air Flow Meter/Sensor: Locations Engine Compartment Views The Mass Air Flow Sensor is located at the center of the engine compartment. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3281 Air Flow Meter/Sensor: Service and Repair 1. Disconnect the battery ground cable. NOTE: The sensing element located inside the Mass Air Flow sensor (MAF sensor) can be damaged by touching. 2. Remove the air cleaner assembly. 3. Separate the two halves of the air cleaner housing. 4. Disconnect the wiring connector from housing. 5. Remove the mounting plate and mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3290 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3291 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3292 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3293 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3294 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3295 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3296 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3297 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3298 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3299 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3300 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3301 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3302 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3308 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3309 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3310 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3311 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3312 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3313 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3314 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3315 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3316 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3317 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3318 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3319 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3320 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3321 Camshaft Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3322 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3323 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. The 4.6L Engine Is Shown; 5.4L And 6.8L Are Similar 2. Remove the Camshaft Position sensor (CMP sensor). 1. Disconnect the electrical connector. 2. Remove the bolt. 3. Remove the CMP sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3327 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3328 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Partially drain the cooling system. 3. Remove the Engine Coolant Temperature sensor (ECT sensor). 1. Disconnect the electrical connector. 2. Remove the ECT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications TORQUE SPECIFICATIONS Crankshaft Position Sensor Bolt ............................................................................................................................................. 8-12 Nm (71-106 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3332 Crankshaft Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3333 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3334 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Release tension on the accessory drive belt. 4. Position the A/C compressor aside. NOTE: Do not remove the lines from the A/C compressor. 5. Disconnect the wiring at the sensor. 6. Remove the CKP sensor bolt and the Crankshaft Position sensor (CKP sensor). NOTE: The crankshaft pulley is shown removed for clarity. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Engine Temperature Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3338 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3339 Engine Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Generator (GEN). 3. Remove cylinder head temperature sensor. 1. Disconnect the electrical connector. 2. Remove the CHT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Full Body Views The Fuel Tank Pressure Sensor is located under LH center of vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3343 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor. 1. Disconnect the electrical connector. 2. Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. Follow the removal procedure in reverse order. 2. Perform the evaporative emission system leak test. 3. Perform the evaporative emission running loss monitor repair verification drive cycle test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Engine Compartment Views The Intake Air Temperature Sensor is located at the Center of the engine compartment, part of clean air tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3347 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly. 3. Disconnect the Intake Air Temperature sensor (IAT sensor) electrical connector, and remove the sensor from the air intake tube. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3351 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3352 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Remove the Knock Sensor (KS). 1. Disconnect the electrical connector. 2. Remove the knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics Oxygen Sensor: Technical Service Bulletins Engine Controls - Bi-Fuel O2 Sensor Diagnostics Article No. 03-6-6 03/31/03 DRIVEABILITY - BI-FUEL - OXYGEN SENSOR DIAGNOSTICS - HIGH OXYGEN SENSOR VOLTAGE READING FORD: 1998-2000 CONTOUR 1998-1999 E SERIES 1998-2003 F-150 1999 F-250 ISSUE Some Bi-Fuel vehicles may exhibit DTC's for high Oxygen Sensor voltage (P0132 and P0152). Current diagnostics may result in premature replacement of the Compuvalve. ACTION If an Oxygen Sensor code is set, the current diagnostics direct the Compuvalve to be replaced it no faults are detected when Pinpoint Test H is conducted. The modified repair action outlined below gives additional test procedures if nothing is detected from Pinpoint Test H. SERVICE PROCEDURE 1. Prior to clearing any codes, to aid in diagnostics of intermittent failures, access and record the freeze frame data using the NGS Tester. 2. At step H4 of the pinpoint test, it Oxygen Sensor PIDS (H02S11 and H02521) are within specification (see table in Section H of PC/ED Manual), clear codes and road test the vehicle in alternative fuel using the freeze frame data (from above) to duplicate conditions that triggered the code. During the road test, monitor Oxygen Sensor PIDs for both banks in both the PCM and the AFCM. NOTE A SECOND TECHNICIAN SHOULD MONITOR THE PIDS WHILE THE OTHER DRIVES. IF THE CODE/CONCERN CANNOT BE DUPLICATED, REFER TO PINPOINT TEST Z OF THE BASE VEHICLE PC/ED. 3. If the concern is duplicated, and if voltage is outside of specifications in both the AFCM and the PCM, the fault is in the Heated Exhaust Gas Oxygen (HEGO) sensor circuit. Refer to base vehicle diagnostics. 4. If the voltage is outside of specifications in the AFCM only, replace the Compuvalve. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 490000, 698298 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3357 Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3358 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3359 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3360 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3361 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3362 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3363 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3364 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3365 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3366 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3367 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3368 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3369 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3370 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3371 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3372 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 3375 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3378 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3379 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3380 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3381 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3382 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3383 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3384 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3385 Oxygen Sensor: Connector Views Ford does not provide connector views for this vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3386 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3387 Oxygen Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the engine cover. 3. Disconnect the wiring. 4. Raise the vehicle. 5. Remove the sensors. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3391 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3395 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3396 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly and throttle body splash shield. 3. Disconnect the wiring at the Throttle Position sensor (TP sensor). 4. Remove the retaining screws and sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor .............................................................................................................................................. 8-10 Nm (75-85 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 3400 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 3401 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 3402 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 3403 Transmission Position Switch/Sensor: Service and Repair Special Tools REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1. Remove the bolts. 2. Remove the sensor. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 3404 1. Install the digital transmission range (TR) sensor. 1. Install the sensor. 2. Loosely install the bolts. 2. Install the Digital Transmission Range (TR) Sensor Alignment Tool. NOTE: Make sure that the manual control lever is in the neutral position. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 3405 5. Reconnect the connector. 6. Reconnect the battery ground cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor-to-Case ....................................................................................................................................................... 49-73 Nm (36-54 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 3409 Vehicle Speed Sensor: Locations Transmission View The Vehicle Speed Sensor is located under vehicle, on the left side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3412 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3413 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3414 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3415 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3416 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3417 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3418 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3419 Vehicle Speed Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the Vehicle Speed Sensor (VSS). 1. Disconnect the VSS electrical connector. 2. Remove the bolt. 3. Remove the VSS. 3. Remove the vehicle speed sensor driven gear. 1. Remove the retaining clip. 2. Remove the driven gear. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3420 1. Install the vehicle speed sensor driven gear. 1. Install the driven gear. 2. Install the retaining clip. 2. Install the Vehicle Speed Sensor (VSS). 1. Install the VSS. 2. Install the bolt. 3. Connect the electrical connector. 3. Lower the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3425 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3435 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3436 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3442 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3443 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3444 Air Flow Meter/Sensor: Locations Engine Compartment Views The Mass Air Flow Sensor is located at the center of the engine compartment. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3445 Air Flow Meter/Sensor: Service and Repair 1. Disconnect the battery ground cable. NOTE: The sensing element located inside the Mass Air Flow sensor (MAF sensor) can be damaged by touching. 2. Remove the air cleaner assembly. 3. Separate the two halves of the air cleaner housing. 4. Disconnect the wiring connector from housing. 5. Remove the mounting plate and mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Full Body Views The Fuel Tank Temperature Sensor is located under LH center of vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Inertia Fuel Shutoff Switch: Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3452 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3453 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. The IFS 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. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3457 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3458 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly and throttle body splash shield. 3. Disconnect the wiring at the Throttle Position sensor (TP sensor). 4. Remove the retaining screws and sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3468 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3469 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3470 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3471 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3472 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3473 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3474 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3475 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3476 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3477 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3478 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3479 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3480 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3486 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3487 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3488 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3489 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3490 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3491 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3492 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3493 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3494 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3495 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3496 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3497 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3498 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3499 Camshaft Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3500 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3501 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. The 4.6L Engine Is Shown; 5.4L And 6.8L Are Similar 2. Remove the Camshaft Position sensor (CMP sensor). 1. Disconnect the electrical connector. 2. Remove the bolt. 3. Remove the CMP sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications TORQUE SPECIFICATIONS Crankshaft Position Sensor Bolt ............................................................................................................................................. 8-12 Nm (71-106 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3505 Crankshaft Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3506 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3507 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Release tension on the accessory drive belt. 4. Position the A/C compressor aside. NOTE: Do not remove the lines from the A/C compressor. 5. Disconnect the wiring at the sensor. 6. Remove the CKP sensor bolt and the Crankshaft Position sensor (CKP sensor). NOTE: The crankshaft pulley is shown removed for clarity. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3516 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3517 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3518 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3519 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3520 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3521 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3522 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3523 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3524 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3525 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3526 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3527 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3528 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 07-11-10 > Jun > 07 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 07-11-10 > Jun > 07 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3538 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 07-11-10 > Jun > 07 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3539 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 07-11-10 > Jun > 07 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3540 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 07-11-10 > Jun > 07 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3541 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 07-11-10 > Jun > 07 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3542 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 07-11-10 > Jun > 07 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3543 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 07-11-10 > Jun > 07 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3544 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 07-11-10 > Jun > 07 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3545 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 07-11-10 > Jun > 07 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3546 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 07-11-10 > Jun > 07 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3547 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 07-11-10 > Jun > 07 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3548 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 07-11-10 > Jun > 07 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3549 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 07-11-10 > Jun > 07 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3550 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > Page 3551 Overdrive Switch: Testing and Inspection For testing procedures for the Transmission Control Switch (TCS), please refer to Pinpoint Test C in Automatic Transmission/Transaxle / Testing and Inspection / Procedures / External Control Diagnostics. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3557 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3558 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3559 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3560 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3561 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3562 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Replacement, Functional Ignition Switch Lock Cylinder: Service and Repair Replacement, Functional REMOVAL NOTE: The following procedure applies to vehicles that have functional lock cylinders and keys. If key numbers are known, the proper key can be made. 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Position the lock cylinder to RUN. (2) Using a suitable tool, push upward on the cylinder release tab through the hole in the lower shroud while pulling the cylinder outward. INSTALLATION 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Replacement, Functional > Page 3565 Ignition Switch Lock Cylinder: Service and Repair Replacement, Non-Functional REMOVAL NOTE: The following procedure applies to vehicles in which the ignition lock is inoperative and the lock cylinder cannot be rotated due to a lost or broken key, unknown key number, or a cap that has been damaged or broken to the extent that the lock cylinder cannot be rotated. 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 1/8 inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8 inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Replacement, Functional > Page 3566 6. Remove the bearing and the gear. - Thoroughly clean all drill shavings from the steering column and inspect it for damage. INSTALLATION 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. NOTE: Use a new ignition switch lock cylinder. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3570 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3571 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Remove the Knock Sensor (KS). 1. Disconnect the electrical connector. 2. Remove the knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service and Repair Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. - BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. 1. Perform the pre-service procedures. 2. Disconnect the battery ground cable. 3. Remove the (B) fuel pressure relief valve from the (A) fuel injection supply manifold. INSTALLATION 1. Install the fuel pressure relief valve and tighten. 2. Connect the battery ground cable. 3. Perform the post-service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Automatic Transmission Idle Speed: Specifications With Automatic Transmission Hot Idle ................................................................................................................................................ ......................................................... 780 - 810 RPM Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Automatic Transmission > Page 3581 Idle Speed: Specifications With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 780 - 810 RPM Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 REMOVAL 1. Lift the engine air cleaner inlet tube and remove. 2. Unlatch the clamp and remove the air cleaner tray. 3. Remove the air cleaner element. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 EFI/CFI Fuel Pressure Gauge WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the fuel pressure gauge. 2. Slowly open the manual valve on the fuel pressure gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place fuel in a suitable container. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order: 1-6-5-10-2-7-3-8-4-9 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark Plug Gap ................................................................................................................................... ................................... 1.32-1.42 mm (0.052-0.056 in) Spark Plug Torque ......................................... ....................................................................................................................................... 9-20 Nm (7-14 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 3601 Spark Plug: Specifications Torque Spark Plug Gap ................................................................................................................................... ................................... 1.32-1.42 mm (0.052-0.056 in) Spark Plug Torque ......................................... ....................................................................................................................................... 9-20 Nm (7-14 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3602 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................ AWSF22E Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3603 Spark Plug: Service and Repair REMOVAL CAUTION: Mark spark plug locations and return to original location. 1. Remove the ignition coil. 2. Remove the spark plug. 3. Inspect the spark plugs; replace if required. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test Compression Check: Testing and Inspection Compression Test 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly 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 five 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. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test > Page 3609 Compression Check: Testing and Inspection Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating improperly. 3. If two 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 percent of the highest reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test > Page 3610 Compression Check: Testing and Inspection Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification WSS-M2C153-F on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3623 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3624 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3630 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3631 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3632 Air Flow Meter/Sensor: Locations Engine Compartment Views The Mass Air Flow Sensor is located at the center of the engine compartment. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3633 Air Flow Meter/Sensor: Service and Repair 1. Disconnect the battery ground cable. NOTE: The sensing element located inside the Mass Air Flow sensor (MAF sensor) can be damaged by touching. 2. Remove the air cleaner assembly. 3. Separate the two halves of the air cleaner housing. 4. Disconnect the wiring connector from housing. 5. Remove the mounting plate and mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Engine Compartment Views The Intake Air Temperature Sensor is located at the Center of the engine compartment, part of clean air tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3637 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly. 3. Disconnect the Intake Air Temperature sensor (IAT sensor) electrical connector, and remove the sensor from the air intake tube. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 3642 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): Customer Interest Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 3651 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 3652 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 3658 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 3659 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Page 3660 Auxiliary Air Valve (Idle Speed): Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Page 3661 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3670 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3671 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3672 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3673 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3674 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3675 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3676 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3677 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3678 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3679 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3680 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3681 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3682 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3688 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3689 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3690 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3691 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3692 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3693 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3694 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3695 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3696 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3697 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3698 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3699 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3700 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3701 Camshaft Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3702 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3703 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. The 4.6L Engine Is Shown; 5.4L And 6.8L Are Similar 2. Remove the Camshaft Position sensor (CMP sensor). 1. Disconnect the electrical connector. 2. Remove the bolt. 3. Remove the CMP sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3707 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3708 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Partially drain the cooling system. 3. Remove the Engine Coolant Temperature sensor (ECT sensor). 1. Disconnect the electrical connector. 2. Remove the ECT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications TORQUE SPECIFICATIONS Crankshaft Position Sensor Bolt ............................................................................................................................................. 8-12 Nm (71-106 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3712 Crankshaft Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3713 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3714 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Release tension on the accessory drive belt. 4. Position the A/C compressor aside. NOTE: Do not remove the lines from the A/C compressor. 5. Disconnect the wiring at the sensor. 6. Remove the CKP sensor bolt and the Crankshaft Position sensor (CKP sensor). NOTE: The crankshaft pulley is shown removed for clarity. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Instrument Panel Views The Data Link Connector is located below LH side of the instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3720 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3721 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3722 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3723 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3724 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3725 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3726 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3727 Data Link Connector Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Engine Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3732 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3733 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3734 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3735 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3736 Engine Control Module: Locations Engine Compartment Views The Powertrain Control Module is located at the left rear of the engine compartment, near brake master cylinder. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3739 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3740 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3741 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3742 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3743 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3744 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3745 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3746 Engine Control Module: Connector Views Powertrain Control Module (Part 1 Of 2) 6.8 L E350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3747 Powertrain Control Module (Part 2 Of 2) 6.8 L E350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Powertrain Control Modules (PCMs) are reprogrammable to update calibration levels without having to replace the PCM. The reprogramming may be performed with the PCM installed in the vehicle using the Service Bay Technical System (SBTS). The PCM may also be reprogrammed outside of the vehicle using the New Generation STAR (NGS) and a 15- to 104- Pin Flash Cable (007-00587 or equivalent). The Flash Cable connects between the NGS and the PCM. The proper calibration must be downloaded to the Data Transfer Card through the SBTS. Follow the download instructions displayed on the NGS screen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3750 Engine Control Module: Reset Procedure NOTE: All OBD II scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears oxygen sensor test data. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation STAR (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTC's. New Generation STAR and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. To reset Keep Alive Random Access Memory, disconnect the battery ground cable for a minimum of 5 minutes. Resetting Keep Alive RAM will clear learned values the PCM has stored for adaptive systems such as idle and fuel trim. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3751 Engine Control Module: Removal and Replacement REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly. 3. Remove the wiring harness retaining bolt and wiring connector cover. 4. Disconnect the wiring harness. 5. Remove the retaining nuts and the Powertrain Control Module (PCM). INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Engine Temperature Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3755 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3756 Engine Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Generator (GEN). 3. Remove cylinder head temperature sensor. 1. Disconnect the electrical connector. 2. Remove the CHT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Full Body Views The Fuel Tank Pressure Sensor is located under LH center of vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3760 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor. 1. Disconnect the electrical connector. 2. Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. Follow the removal procedure in reverse order. 2. Perform the evaporative emission system leak test. 3. Perform the evaporative emission running loss monitor repair verification drive cycle test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Service and Repair Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly and the throttle body splash guard. 3. Remove the engine cover. 4. Disconnect the wiring and air hose at the Idle Air Control valve (IAC valve). 5. Remove the retaining bolts and idle air control valve. Discard the gasket. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Specifications Information Bus: Specifications Heat Shrink Tube Overlap ................................................................................................................... ......................................................... 12.7 mm (0.5 in) Wire Insulation Removal Length (Twist Side) ............................................................................................................................................. 37.2 mm (1.5 in) Wire Insulation Removal Length (Receiving Side) .................................................................................................................................... 19.5 mm (0.75 in) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3769 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3770 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3771 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3772 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3773 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3774 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3775 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3776 Multiplex Communication Network Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 3777 Information Bus: Description and Operation The vehicle has two module communication networks: The Standard Corporate Protocol (SCP) network, which is an unshielded twisted pair of wires (data bus plus, circuit 914 and data bus minus, circuit 915), and the International Standards Organization (ISO) 9141 network which is a single wire (circuit 70 [/W]). Both networks can be connected to New Generation STAR (NGS) Tester at one connector called the Data Link Connector (DLC). This makes troubleshooting these systems easier by allowing one tester to be able to diagnose and control any module on the two networks from one connector. The DLC can be found under the instrument panel directly below the steering column. The ISO 9141 network does not permit inter-module communication. When NGS Tester communicates to modules on the ISO 9141 network, NGS Tester must ask for all information; the modules cannot initiate communications. The SCP network will remain operational even with the severing of one of the bus wires. Communications will also continue if one of the bus wires is shorted to chassis ground or battery positive voltage (B+) or a termination resistor is lost. This faulted condition is detected and reported to the host by the module's network bus interface circuits. Unlike the SCP, the ISO 9141 network will not function if the wire is shorted to chassis ground or battery positive voltage (B+). Also, if one of the modules on the ISO 9141 network loses power or shorts internally, communications to that module will fail. There are two modules on each network. Module Configuration The Powertrain Control Module (PCM) is on the SCP communication network. The PCM controls the engine for better fuel economy, emissions control and failure mode detection and storage. The air bag Electronic Crash Sensor (ECS) module is on the ISO 9141 network. The ECS controls the deployment of the air bags based on sensor input. The 4-Wheel Anti-lock Brake System (4WABS) is on the ISO 9141 network. The 4WABS controls the brake pressure to the four wheels to keep the vehicle under control while braking. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis Information Bus: Flow of Diagnosis 1. Verify the customer concern. 2. Visually inspect the following for obvious signs of electrical damage: VISUAL INSPECTION CHART Electrical Fuses - Damaged wiring harness - Loose or corroded connectors - 4-wheel anti-lock brake control module - Electronic Crash Sensor (ECS) module - Powertrain Control Module (PCM) - Natural Gas Vehicle Module (NGVM) - Auxiliary Powertrain Control Module (APCM) 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS Tester menu. If the NGS Tester does not communicate with the vehicle: check that the program card is properly installed. - check the connections to the vehicle. - check the ignition switch position. If the NGS still does not communicate with the vehicle, go to Pinpoint Test H. See: Pinpoint Tests/H: No Module/Network Communication 4. Go to Pinpoint Test PC. See: Initial Inspection and Diagnostic Overview/System Precheck Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3780 Information Bus: Initial Inspection and Diagnostic Overview PC1 Inspection and Verification 1. Verify the customer concern. 2. Visually inspect the following for obvious signs of electrical damage: VISUAL INSPECTION CHART Electrical Fuses - Damaged wiring harness - Loose or corroded connectors - 4-wheel anti-lock brake control module - Electronic Crash Sensor (ECS) module - Powertrain Control Module (PCM) - Natural Gas Vehicle Module (NGVM) - Auxiliary Powertrain Control Module (APCM) 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS Tester menu. If the NGS Tester does not communicate with the vehicle: check that the program card is properly installed. - check the connections to the vehicle. - check the ignition switch position. If the NGS still does not communicate with the vehicle, go to Pinpoint Test H. See: Pinpoint Tests/H: No Module/Network Communication 4. Go to Pinpoint Test PC. See: System Precheck Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3781 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3782 Information Bus: Pinpoint Tests A: The Four Wheel ABS Module Does Not Respond to NGS Tester A1 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3783 A2 - A3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3784 A4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3785 B1 - B2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3786 B3 - B4 C: The Powertrain Control Module Doesn't Respond to NGS Tester C1 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3787 C2 - C3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3788 C4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3789 D1 - D2 F: No Module/Network Communication - ISO 9141 Network Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3790 F1 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3791 F2 - F3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3792 F4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3793 F5 - F6 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3794 F7 G: No Module/Network Communication - SCP Network G1 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3795 G2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3796 G3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3797 G4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3798 G5 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3799 G6 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3800 G7 H: No Module/Network Communication Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3801 H1 - H2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3802 H3 - H4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3803 H5 - H6 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 3804 Information Bus: Service and Repair Rotunda Heat Gun Special Tool(s) COMMUNICATION CIRCUIT WIRING REPAIR NOTE: If either circuit 914 or circuit 915 is repaired or replaced without using the following procedure, the operation of the Multiplex Communication Network (MCN) will be degraded. - Circuit 914 and circuit 915 must be twisted at a rate of 33-40 twists per meter before the replacement of either circuit. The twist must be within 10 centimeters of any connector termination point. - The durability of a wire splice is dependent on getting a joint that does not oxidize. Soldering is effective in keeping the air (oxide) out of the joined electronic circuits. Very high current circuits can fail because of oxidized joints that are not visible with the naked eye. The durability of a splice is also dependent on keeping moisture out of the joint. Heat shrink tubing alone will not seal it. The tubing must contain a hot melt wax, which is squeezed from both ends of the tubing during heating and forms an adhesive seal between the wire insulation and the tubing. Use Raychem SCT(R) heat shrink tubing, Motorcraft part number WT5627 or equivalent meeting Ford specification ESB-M99D56-A2. - Use the following procedure any time a twisted pair of circuits or circuit 70 (LB/W) is repaired. 1. Disconnect the battery ground cable. 2. Strip both wires to specification. 1 Strip one wire to expose 38 mm (1.5 in) of bare wire. 2 Strip the second wire to expose 19 mm (0.75 in) of bare wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 3805 3. Twist and solder the wires together. 1 Install the heat shrink tube. 2 Twist 12.7 mm (0.5 in) of each wire together. CAUTION: Use Resin Core Mildly Activated (RMA) solder. Do not use acid core solder. 4. Form (bend) the circuit into shape for sealing. NOTE: Wait for the solder to cool before moving the wires. 5. Position the heat shrink tube over the splice. 6. Shrink the heat shrink tube on the exposed circuit with a heat gun. 1 Heat the heat shrink tube with the heat gun. 2 Remove the heat when the hot wax flows out of both ends of the heat shrink tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 3806 7. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 3807 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3811 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3812 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Remove the Knock Sensor (KS). 1. Disconnect the electrical connector. 2. Remove the knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3816 Engine Compartment Fuse Box (Part 2 Of 2) The PCM Power Relay is located at LH front of engine compartment, in engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics Oxygen Sensor: Technical Service Bulletins Engine Controls - Bi-Fuel O2 Sensor Diagnostics Article No. 03-6-6 03/31/03 DRIVEABILITY - BI-FUEL - OXYGEN SENSOR DIAGNOSTICS - HIGH OXYGEN SENSOR VOLTAGE READING FORD: 1998-2000 CONTOUR 1998-1999 E SERIES 1998-2003 F-150 1999 F-250 ISSUE Some Bi-Fuel vehicles may exhibit DTC's for high Oxygen Sensor voltage (P0132 and P0152). Current diagnostics may result in premature replacement of the Compuvalve. ACTION If an Oxygen Sensor code is set, the current diagnostics direct the Compuvalve to be replaced it no faults are detected when Pinpoint Test H is conducted. The modified repair action outlined below gives additional test procedures if nothing is detected from Pinpoint Test H. SERVICE PROCEDURE 1. Prior to clearing any codes, to aid in diagnostics of intermittent failures, access and record the freeze frame data using the NGS Tester. 2. At step H4 of the pinpoint test, it Oxygen Sensor PIDS (H02S11 and H02521) are within specification (see table in Section H of PC/ED Manual), clear codes and road test the vehicle in alternative fuel using the freeze frame data (from above) to duplicate conditions that triggered the code. During the road test, monitor Oxygen Sensor PIDs for both banks in both the PCM and the AFCM. NOTE A SECOND TECHNICIAN SHOULD MONITOR THE PIDS WHILE THE OTHER DRIVES. IF THE CODE/CONCERN CANNOT BE DUPLICATED, REFER TO PINPOINT TEST Z OF THE BASE VEHICLE PC/ED. 3. If the concern is duplicated, and if voltage is outside of specifications in both the AFCM and the PCM, the fault is in the Heated Exhaust Gas Oxygen (HEGO) sensor circuit. Refer to base vehicle diagnostics. 4. If the voltage is outside of specifications in the AFCM only, replace the Compuvalve. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 490000, 698298 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3821 Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3822 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3823 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3824 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3825 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3826 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3827 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3828 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3829 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3830 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3831 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3832 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3833 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3834 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3835 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3836 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 3839 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3842 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3843 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3844 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3845 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3846 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3847 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3848 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3849 Oxygen Sensor: Connector Views Ford does not provide connector views for this vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3850 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3851 Oxygen Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the engine cover. 3. Disconnect the wiring. 4. Raise the vehicle. 5. Remove the sensors. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3855 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 3861 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures Engine Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures > Page 3866 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures > Page 3867 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures > Page 3868 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures > Page 3869 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3870 Engine Control Module: Locations Engine Compartment Views The Powertrain Control Module is located at the left rear of the engine compartment, near brake master cylinder. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3873 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3874 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3875 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3876 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3877 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3878 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3879 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3880 Engine Control Module: Connector Views Powertrain Control Module (Part 1 Of 2) 6.8 L E350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3881 Powertrain Control Module (Part 2 Of 2) 6.8 L E350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Powertrain Control Modules (PCMs) are reprogrammable to update calibration levels without having to replace the PCM. The reprogramming may be performed with the PCM installed in the vehicle using the Service Bay Technical System (SBTS). The PCM may also be reprogrammed outside of the vehicle using the New Generation STAR (NGS) and a 15- to 104- Pin Flash Cable (007-00587 or equivalent). The Flash Cable connects between the NGS and the PCM. The proper calibration must be downloaded to the Data Transfer Card through the SBTS. Follow the download instructions displayed on the NGS screen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3884 Engine Control Module: Reset Procedure NOTE: All OBD II scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears oxygen sensor test data. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation STAR (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTC's. New Generation STAR and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. To reset Keep Alive Random Access Memory, disconnect the battery ground cable for a minimum of 5 minutes. Resetting Keep Alive RAM will clear learned values the PCM has stored for adaptive systems such as idle and fuel trim. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3885 Engine Control Module: Removal and Replacement REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly. 3. Remove the wiring harness retaining bolt and wiring connector cover. 4. Disconnect the wiring harness. 5. Remove the retaining nuts and the Powertrain Control Module (PCM). INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 3889 Engine Compartment Fuse Box (Part 2 Of 2) The PCM Power Relay is located at LH front of engine compartment, in engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3899 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3900 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3906 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3907 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: All Technical Service Bulletins Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 3913 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 3914 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 3920 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 3921 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3922 Air Flow Meter/Sensor: Locations Engine Compartment Views The Mass Air Flow Sensor is located at the center of the engine compartment. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3923 Air Flow Meter/Sensor: Service and Repair 1. Disconnect the battery ground cable. NOTE: The sensing element located inside the Mass Air Flow sensor (MAF sensor) can be damaged by touching. 2. Remove the air cleaner assembly. 3. Separate the two halves of the air cleaner housing. 4. Disconnect the wiring connector from housing. 5. Remove the mounting plate and mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3932 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3933 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3934 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3935 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3936 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3937 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3938 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3939 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3940 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3941 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3942 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3943 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3944 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3950 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3951 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3952 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3953 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3954 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3955 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3956 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3957 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3958 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3959 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3960 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3961 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3962 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3963 Camshaft Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3964 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3965 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. The 4.6L Engine Is Shown; 5.4L And 6.8L Are Similar 2. Remove the Camshaft Position sensor (CMP sensor). 1. Disconnect the electrical connector. 2. Remove the bolt. 3. Remove the CMP sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3969 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3970 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Partially drain the cooling system. 3. Remove the Engine Coolant Temperature sensor (ECT sensor). 1. Disconnect the electrical connector. 2. Remove the ECT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications TORQUE SPECIFICATIONS Crankshaft Position Sensor Bolt ............................................................................................................................................. 8-12 Nm (71-106 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3974 Crankshaft Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3975 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3976 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Release tension on the accessory drive belt. 4. Position the A/C compressor aside. NOTE: Do not remove the lines from the A/C compressor. 5. Disconnect the wiring at the sensor. 6. Remove the CKP sensor bolt and the Crankshaft Position sensor (CKP sensor). NOTE: The crankshaft pulley is shown removed for clarity. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Engine Temperature Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3980 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3981 Engine Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Generator (GEN). 3. Remove cylinder head temperature sensor. 1. Disconnect the electrical connector. 2. Remove the CHT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Full Body Views The Fuel Tank Pressure Sensor is located under LH center of vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3985 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor. 1. Disconnect the electrical connector. 2. Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. Follow the removal procedure in reverse order. 2. Perform the evaporative emission system leak test. 3. Perform the evaporative emission running loss monitor repair verification drive cycle test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Engine Compartment Views The Intake Air Temperature Sensor is located at the Center of the engine compartment, part of clean air tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3989 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly. 3. Disconnect the Intake Air Temperature sensor (IAT sensor) electrical connector, and remove the sensor from the air intake tube. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3993 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3994 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Remove the Knock Sensor (KS). 1. Disconnect the electrical connector. 2. Remove the knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics Oxygen Sensor: Technical Service Bulletins Engine Controls - Bi-Fuel O2 Sensor Diagnostics Article No. 03-6-6 03/31/03 DRIVEABILITY - BI-FUEL - OXYGEN SENSOR DIAGNOSTICS - HIGH OXYGEN SENSOR VOLTAGE READING FORD: 1998-2000 CONTOUR 1998-1999 E SERIES 1998-2003 F-150 1999 F-250 ISSUE Some Bi-Fuel vehicles may exhibit DTC's for high Oxygen Sensor voltage (P0132 and P0152). Current diagnostics may result in premature replacement of the Compuvalve. ACTION If an Oxygen Sensor code is set, the current diagnostics direct the Compuvalve to be replaced it no faults are detected when Pinpoint Test H is conducted. The modified repair action outlined below gives additional test procedures if nothing is detected from Pinpoint Test H. SERVICE PROCEDURE 1. Prior to clearing any codes, to aid in diagnostics of intermittent failures, access and record the freeze frame data using the NGS Tester. 2. At step H4 of the pinpoint test, it Oxygen Sensor PIDS (H02S11 and H02521) are within specification (see table in Section H of PC/ED Manual), clear codes and road test the vehicle in alternative fuel using the freeze frame data (from above) to duplicate conditions that triggered the code. During the road test, monitor Oxygen Sensor PIDs for both banks in both the PCM and the AFCM. NOTE A SECOND TECHNICIAN SHOULD MONITOR THE PIDS WHILE THE OTHER DRIVES. IF THE CODE/CONCERN CANNOT BE DUPLICATED, REFER TO PINPOINT TEST Z OF THE BASE VEHICLE PC/ED. 3. If the concern is duplicated, and if voltage is outside of specifications in both the AFCM and the PCM, the fault is in the Heated Exhaust Gas Oxygen (HEGO) sensor circuit. Refer to base vehicle diagnostics. 4. If the voltage is outside of specifications in the AFCM only, replace the Compuvalve. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 490000, 698298 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3999 Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4000 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4001 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4002 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4003 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4004 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4005 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4006 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4007 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4008 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4009 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4010 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4011 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4012 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4013 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4014 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 4017 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4020 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4021 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4022 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4023 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4024 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4025 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4026 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4027 Oxygen Sensor: Connector Views Ford does not provide connector views for this vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4028 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4029 Oxygen Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the engine cover. 3. Disconnect the wiring. 4. Raise the vehicle. 5. Remove the sensors. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 4033 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4037 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4038 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly and throttle body splash shield. 3. Disconnect the wiring at the Throttle Position sensor (TP sensor). 4. Remove the retaining screws and sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor .............................................................................................................................................. 8-10 Nm (75-85 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4042 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4043 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4044 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4045 Transmission Position Switch/Sensor: Service and Repair Special Tools REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1. Remove the bolts. 2. Remove the sensor. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4046 1. Install the digital transmission range (TR) sensor. 1. Install the sensor. 2. Loosely install the bolts. 2. Install the Digital Transmission Range (TR) Sensor Alignment Tool. NOTE: Make sure that the manual control lever is in the neutral position. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4047 5. Reconnect the connector. 6. Reconnect the battery ground cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor-to-Case ....................................................................................................................................................... 49-73 Nm (36-54 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 4051 Vehicle Speed Sensor: Locations Transmission View The Vehicle Speed Sensor is located under vehicle, on the left side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4054 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4055 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4056 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4057 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4058 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4059 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4060 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4061 Vehicle Speed Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the Vehicle Speed Sensor (VSS). 1. Disconnect the VSS electrical connector. 2. Remove the bolt. 3. Remove the VSS. 3. Remove the vehicle speed sensor driven gear. 1. Remove the retaining clip. 2. Remove the driven gear. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4062 1. Install the vehicle speed sensor driven gear. 1. Install the driven gear. 2. Install the retaining clip. 2. Install the Vehicle Speed Sensor (VSS). 1. Install the VSS. 2. Install the bolt. 3. Connect the electrical connector. 3. Lower the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4066 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4067 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly and throttle body splash shield. 3. Disconnect the wiring at the Throttle Position sensor (TP sensor). 4. Remove the retaining screws and sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor .............................................................................................................................................. 8-10 Nm (75-85 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4071 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4072 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4073 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4074 Transmission Position Switch/Sensor: Service and Repair Special Tools REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1. Remove the bolts. 2. Remove the sensor. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4075 1. Install the digital transmission range (TR) sensor. 1. Install the sensor. 2. Loosely install the bolts. 2. Install the Digital Transmission Range (TR) Sensor Alignment Tool. NOTE: Make sure that the manual control lever is in the neutral position. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4076 5. Reconnect the connector. 6. Reconnect the battery ground cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor-to-Case ....................................................................................................................................................... 49-73 Nm (36-54 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 4080 Vehicle Speed Sensor: Locations Transmission View The Vehicle Speed Sensor is located under vehicle, on the left side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4083 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4084 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4085 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4086 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4087 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4088 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4089 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4090 Vehicle Speed Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the Vehicle Speed Sensor (VSS). 1. Disconnect the VSS electrical connector. 2. Remove the bolt. 3. Remove the VSS. 3. Remove the vehicle speed sensor driven gear. 1. Remove the retaining clip. 2. Remove the driven gear. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4091 1. Install the vehicle speed sensor driven gear. 1. Install the driven gear. 2. Install the retaining clip. 2. Install the Vehicle Speed Sensor (VSS). 1. Install the VSS. 2. Install the bolt. 3. Connect the electrical connector. 3. Lower the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise Catalyst Shield: Customer Interest Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 4102 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 4103 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 4109 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 4110 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalyst Shield: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: All Technical Service Bulletins Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalyst Shield: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 4116 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalyst Shield: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 4117 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalyst Shield: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 4123 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalyst Shield: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 4124 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair Canister Purge Control Valve: Service and Repair REMOVAL WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL IS PRESENT IN THE AREA. 1. Disconnect the battery ground cable. 2. Disconnect the fuel vapor management valve electrical connector and the evaporative emission vacuum control hose. 3. Disconnect the two evaporative emission return tubes. 4. Remove the nuts and remove the evaporative emission canister purge valve (EVAP canister purge valve). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair > Page 4129 INSTALLATION 1. Connect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. Follow the removal procedure in reverse order. 3. Perform the evaporative emission system leak test. See: Testing and Inspection/Component Tests/EVAP System Leak Test 4. Perform the evaporative emission running loss monitor repair verification drive cycle test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Canister Purge Solenoid: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 4133 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications Evaporative Emission Control Canister: Specifications Evaporative Emissions Canister Nut ................................................................................................................................................ 15-20 Nm (11-14 Lb/In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4137 Evaporative Emission Control Canister: Service and Repair REMOVAL WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL IS PRESENT IN THE AREA. 1. Raise and support the vehicle. 2. Loosen the clamps and remove the evaporative emission return tubes. 3. Remove the nuts and remove canister and bracket assembly. 4. If required, remove the retainer by sliding the retainer off the bracket. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4138 5. Remove the evaporative emissions canister vent valve. NOTE: - Inspect and replace the O-ring as necessary. - A twisting and pulling motion is required to remove the evaporative emissions canister vent valve. 6. Remove the evaporative emissions canister outlet elbow. NOTE: - Inspect and replace the O-ring as necessary. - If required, a twisting and pulling motion is required to remove the inlet fitting. 7. Remove the evaporative emissions canister (EVAP canister). 1. Remove the bolt and mounting bracket. 2. Remove the evaporative emissions canister. INSTALLATION 1. Follow the removal procedure in reverse order. CAUTION: The leak test for the choke plate adjustment swivel must be performed prior to its installation on the vehicle. NOTE: Lubricate the O-ring seals with MerPol or equivalent meeting Ford specification ESE-M99B144-B. 2. Perform the evaporative emission canister assembly leak test. See: Testing and Inspection/Component Tests/Evaporative Emission Canister Assembly Leak Test 3. Perform the evaporative emission running loss monitor repair verification drive cycle test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Service and Repair Evaporative System Service Port: Service and Repair REMOVAL 1. Remove the air cleaner inlet tube. 2. Insert a small screwdriver into the locking mechanism on the evaporative emission test port retainer (the protective cap can be removed for easier access). 3. Open the attaching clip and remove it from the transmission fluid level tube assembly. 4. Pull the evaporative emission test port tube loose from the clip. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Service and Repair > Page 4142 5. Remove the inside engine cover and disconnect the evaporative emission test port tube from the vacuum connection. INSTALLATION 1. Follow the removal procedure in reverse order. 2. Perform the evaporative emission canister assembly leak test. See: Testing and Inspection/Component Tests/Evaporative Emission Canister Assembly Leak Test 3. Perform the evaporative emission running loss monitor repair verification drive cycle test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations EGR Control Solenoid: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 4147 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 4151 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 4156 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service and Repair Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. - BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. 1. Perform the pre-service procedures. 2. Disconnect the battery ground cable. 3. Remove the (B) fuel pressure relief valve from the (A) fuel injection supply manifold. INSTALLATION 1. Install the fuel pressure relief valve and tighten. 2. Connect the battery ground cable. 3. Perform the post-service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair EFI/CFI Fuel Pressure Gauge WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the fuel pressure gauge. 2. Slowly open the manual valve on the fuel pressure gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place fuel in a suitable container. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > With Automatic Transmission Idle Speed: Specifications With Automatic Transmission Hot Idle ................................................................................................................................................ ......................................................... 780 - 810 RPM Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > With Automatic Transmission > Page 4169 Idle Speed: Specifications With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 780 - 810 RPM Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 4174 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Pedal and Shaft Bolts .................................................................................................................................................... 22-28 Nm (16-21 Lb/Ft) Accelerator Cable Bracket Bolts ...................................................................................................................................................... 9-12 Nm (80-106 Lb/In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 4178 Accelerator Pedal: Description and Operation The throttle is controlled by an accelerator cable attached to the accelerator pedal and shaft. The accelerator pedal and shaft should travel smoothly from the idle to the wide open throttle positions. Hesitation on return or prevention of return to the idle position must not occur. Surrounding components such as wiring, hoses, sound insulator and floor carpet must not contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft. The throttle assembly is not adjustable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accelerator Pedal: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the acceleration control system to duplicate the condition. 2. Inspect to determine if any of the following mechanical concerns apply. Visual Inspection Chart Mechanical - Damage accelerator pedal and shaft. - Damaged linkage. - Damaged accelerator cable. - High engine idle speed. - Damaged throttle body. 3. If the inspection reveals an obvious concern that can be readily identified, repair it as required. 4. If the concern remains after the inspection, determine the symptom(s) and go to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4181 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Page 4182 Accelerator Pedal: Service and Repair REMOVAL 1. Hold the accelerator pedal in place and disconnect the accelerator cable from the accelerator pedal and shaft. 2. Remove the bolts retaining the accelerator pedal and shaft. 3. Remove the accelerator pedal and shaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Page 4183 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 REMOVAL 1. Lift the engine air cleaner inlet tube and remove. 2. Unlatch the clamp and remove the air cleaner tray. 3. Remove the air cleaner element. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4196 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4197 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 4203 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 4204 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Speaker: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 4210 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 4211 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 4212 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 4213 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 4214 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 4215 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 4216 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 4222 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 4223 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 4224 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 4225 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 4226 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 4227 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 4228 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4229 Air Flow Meter/Sensor: Locations Engine Compartment Views The Mass Air Flow Sensor is located at the center of the engine compartment. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4230 Air Flow Meter/Sensor: Service and Repair 1. Disconnect the battery ground cable. NOTE: The sensing element located inside the Mass Air Flow sensor (MAF sensor) can be damaged by touching. 2. Remove the air cleaner assembly. 3. Separate the two halves of the air cleaner housing. 4. Disconnect the wiring connector from housing. 5. Remove the mounting plate and mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): Customer Interest Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4239 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4240 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4246 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4247 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Page 4248 Auxiliary Air Valve (Idle Speed): Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Page 4249 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns Fuel: Technical Service Bulletins Fuel - Volatility Related Driveability Concerns Article No. 98-26-2 01/04/99 FUEL - INFORMATION ON GASOLINE - TIPS TO RESOLVE VOLATILITY RELATED DRIVEABILITY CONCERNS FORD: 1985-97 THUNDERBIRD 1986-99 MUSTANG, TAURUS 1987-99 ESCORT 1988-94 TEMPO 1989-97 PROBE 1990-99 CROWN VICTORIA 1992-93 FESTIVA 1995-99 CONTOUR LINCOLN-MERCURY: 1985-97 COUGAR 1986-92 MARK VII 1986-99 SABLE 1987-89 TRACER 1988-94 TOPAZ 1988-99 CONTINENTAL 1990-99 GRAND MARQUIS, TOWN CAR 1991-99 TRACER 1993-98 MARK VIII 1995-99 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1986-97 AEROSTAR 1987-96 BRONCO 1989-97 F SUPER DUTY, F-350 1989-99 F-150, F-250 LD, RANGER 1991-99 EXPLORER 1992-99 ECONOLINE 1993-99 VILLAGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1990-97 F-700 This TSB article is being republished in its entirety to expand vehicle model coverage and revise the text. ISSUE Some vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard start condition or a no start condition in unseasonably hot weather (greater than 27°C/80°F). These concerns may be related to fuel volatility from winter blend fuels during winter-spring and autumn-winter transitions and may result in a fuel pump vapor lock condition. This condition may appear to be a fuel pump failure but may be caused by winter blend fuel. ACTION Refer to the following text for further information. NOTE FUEL TANK ADDITIVES WILL NOT RESOLVE THESE CONCERNS BECAUSE VAPOR FORMS FROM CAVITATION WITHIN THE FUEL PUMP. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns > Page 4254 FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE RECOMMENDED OCTANE GRADE PER OWNER MANUAL AND NOT A HIGHER GRADE. Explain to the customer that this concern may be due to a low tank level of winter blend fuel combined with unseasonably warm weather. Advise customer that filling the fuel tank to full may be effective in resolving this concern. Also, advise customer to use the recommended octane grade per their Owner Manual and not a higher grade. BACKGROUND Gasolines are seasonally adjusted, meaning they have higher volatility (vaporize easier) in the winter and lower volatility in the summer. Government mandates to improve air quality have resulted in significant changes to gasolines, such as the mandatory use of oxygenates (ethanol, methyl tertiary butyl ether (MTBE), and others) in the winter or the reduction of Reid Vapor Pressure (RVP) in the summer. The addition of oxygenates (especially ethanol) increases volatility while the reduction of RVP reduces volatility. Gasoline distribution practices often do not allow branded marketers to have much control over their gasoline's volatility other than RVP. Oxygenate (e.g., ethanol, MTBE) use is more dependent on local gasoline markets, rather than specific marketers practice. Therefore, it is difficult to recommend specific brands to avoid volatility related complaints. OTHER APPLICABLE ARTICLES: 91-8-13 SUPERSEDES: 96-5-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:402000, 404000, 602300, 603300, 607000, 607400, 608000, 608400, 609000, 609400, 610000, 611000, 611500, 612000, 614000, 614500, 623000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Cut Valve Solenoid (CNG) > Component Information > Technical Service Bulletins > Bi-Fuel - Lock Off Solenoid/Tank Valve Coil Resistance Fuel Cut Valve Solenoid (CNG): Technical Service Bulletins Bi-Fuel - Lock Off Solenoid/Tank Valve Coil Resistance Article No. 01-21-4 10/29/01 DRIVEABILITY - BI-FUEL - LOCK-OFF SOLENOID AND SOLENOID TANK VALVE COIL RESISTANCE CHART - SERVICE TIPS FORD: 1996-2000 CONTOUR 1996 E SERIES, F-150 1998-1999 E SERIES 1998-2001 F-150 1999-2001 SUPER DUTY F SERIES ISSUE This article can be used as an aid in diagnosis for clarification of lock-off solenoid and solenoid tank valve coil resistances for Bi-Fuel vehicles. ACTION Refer to the Bi-Fuel Lock-Off Solenoid And Solenoid Tank Valve Coil Resistance Chart. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Cut Valve Solenoid (LPG) > Component Information > Technical Service Bulletins > Bi-Fuel - Lock Off Solenoid/Tank Valve Coil Resistance Fuel Cut Valve Solenoid (LPG): Technical Service Bulletins Bi-Fuel - Lock Off Solenoid/Tank Valve Coil Resistance Article No. 01-21-4 10/29/01 DRIVEABILITY - BI-FUEL - LOCK-OFF SOLENOID AND SOLENOID TANK VALVE COIL RESISTANCE CHART - SERVICE TIPS FORD: 1996-2000 CONTOUR 1996 E SERIES, F-150 1998-1999 E SERIES 1998-2001 F-150 1999-2001 SUPER DUTY F SERIES ISSUE This article can be used as an aid in diagnosis for clarification of lock-off solenoid and solenoid tank valve coil resistances for Bi-Fuel vehicles. ACTION Refer to the Bi-Fuel Lock-Off Solenoid And Solenoid Tank Valve Coil Resistance Chart. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve Rough Idle Speed/Stalls at Idle Speeds Fuel Distributor: Customer Interest Compuvalve - Rough Idle Speed/Stalls at Idle Speeds Article No. 00-10-4 05/15/00 ^ IDLE - ROUGH IDLE SPEED - BI-FUEL VEHICLES ONLY ^ STALL - DURING IDLE SPEEDS - BI-FUEL VEHICLES ONLY FORD: 1998-1999 E-250, E-350, F-150, F-250 LD ISSUE On some vehicles vaporizers with GFI model numbers Z5-1OO or Z7-1OO, may experience internal component deterioration due to fuel contamination. ACTION The following procedures are provided to expedite diagnostics and to determine if component debris (caused by fuel contamination) has impeded the operation of the Vaporizer, Compuvalve, Fuel Rails, and/or Injector Sleeves. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform all preliminary diagnostics as indicated in the Workshop Manual/Workshop information CD to ensure that the base vehicle is operational. Even a weak ignition system may cause a driveability concern in ALT fuel while not affecting gasoline. Use the NGS to verify that the PCM calibration matches the current bi-fuel calibration code in the following Calibration Chart. Confirm and record the model number of the vaporizer for the vehicle. On the F-Series truck, a mirror can be used to read the model number and on the Econoline van, unbolt the vaporizer from the bracket to read the model number. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve Rough Idle Speed/Stalls at Idle Speeds > Page 4271 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve Rough Idle Speed/Stalls at Idle Speeds > Page 4272 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve Rough Idle Speed/Stalls at Idle Speeds > Page 4273 If the Vaporizer model number is not labeled Z5-1OO or Z7-1OO follow the procedures outlined in the Workshop Manual/Workshop information CD. If the Vaporizer model number is labeled Z5-1OO or Z7-1OO, continue with the following service procedure (Figures 1-3). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve Rough Idle Speed/Stalls at Idle Speeds > Page 4274 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 603300, 607000, 607400, 608000, 608400, 609000, 609400 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds Fuel Distributor: All Technical Service Bulletins Compuvalve - Rough Idle Speed/Stalls at Idle Speeds Article No. 00-10-4 05/15/00 ^ IDLE - ROUGH IDLE SPEED - BI-FUEL VEHICLES ONLY ^ STALL - DURING IDLE SPEEDS - BI-FUEL VEHICLES ONLY FORD: 1998-1999 E-250, E-350, F-150, F-250 LD ISSUE On some vehicles vaporizers with GFI model numbers Z5-1OO or Z7-1OO, may experience internal component deterioration due to fuel contamination. ACTION The following procedures are provided to expedite diagnostics and to determine if component debris (caused by fuel contamination) has impeded the operation of the Vaporizer, Compuvalve, Fuel Rails, and/or Injector Sleeves. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform all preliminary diagnostics as indicated in the Workshop Manual/Workshop information CD to ensure that the base vehicle is operational. Even a weak ignition system may cause a driveability concern in ALT fuel while not affecting gasoline. Use the NGS to verify that the PCM calibration matches the current bi-fuel calibration code in the following Calibration Chart. Confirm and record the model number of the vaporizer for the vehicle. On the F-Series truck, a mirror can be used to read the model number and on the Econoline van, unbolt the vaporizer from the bracket to read the model number. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4280 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4281 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4282 If the Vaporizer model number is not labeled Z5-1OO or Z7-1OO follow the procedures outlined in the Workshop Manual/Workshop information CD. If the Vaporizer model number is labeled Z5-1OO or Z7-1OO, continue with the following service procedure (Figures 1-3). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4283 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 603300, 607000, 607400, 608000, 608400, 609000, 609400 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4292 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4293 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4294 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4295 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4296 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4302 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4303 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4304 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4305 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4306 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filler Cap: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: All Technical Service Bulletins Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 EFI/CFI Fuel Pressure Gauge WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the fuel pressure gauge. 2. Slowly open the manual valve on the fuel pressure gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place fuel in a suitable container. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair Fuel Injector Wiring Harness: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. - BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. 1. Disconnect the battery ground cable. 2. Perform the pre-service procedures. 3. Remove the engine cover. 4. Remove the engine air cleaner and the air cleaner outlet tube. 5. Remove the accelerator splash shield. 6. Working from the front of the engine, disconnect the (A) engine coolant temperature sensor connector, the (B) intake manifold air control valve assembly connector, and the (C) camshaft position sensor connector. 7. From underneath the vehicle, disconnect the A/C compressor connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 4325 8. From underneath the engine, disconnect the (A) oil pressure sensor connector from the (B) oil filter adapter. 9. Disconnect the crankshaft position sensor connector. 10. From the top of the engine, disconnect the idle air control valve connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 4326 11. Disconnect the throttle position sensor connector. 12. Disconnect the electronic vacuum regulator connector and the EGR transducer connector. 13. Disconnect the cylinder head temperature sensor jumper. 14. Disconnect the engine knock sensor connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 4327 15. On the left side of the engine, disconnect the five fuel injector connectors and the five ignition coil connectors. 16. On the right side of the engine, remove the five fuel injector connectors and the five ignition coil connectors. 17. At the rear of the right cylinder head, disconnect the radio capacitor connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 4328 18. At the right front of the engine, disconnect the (A) 42-pin connector and the two (B) 16-pin connectors. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting Fuel Line Coupler: Service and Repair Hairpin Clip Fitting DISCONNECT WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. Relieve the fuel pressure. 2. Remove the shipping tab by bending it downward. 3. Spread the hairpin clip legs and push the clip into the fitting. 4. Separate the fitting from the tube. CONNECT 1. Inspect the fitting and the tube for damage. Remove any dirt or obstructions. 2. Apply a light coat of clean engine oil to the male tube end. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4333 3. Insert the hairpin clip into the fitting. 4. Align the tube and the fitting. 5. Insert the tube in the fitting and push together until a click is heard. 6. Pull on the connection to make sure it is fully engaged. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4334 Fuel Line Coupler: Service and Repair Vapor Tube Fittings DISCONNECT 1. Disconnect the vapor tube from the fitting. - Squeeze the fitting. - Disconnect the vapor tube from the fitting. CONNECT 1. Inspect the fitting and the tube for damage. 2. Remove any dirt or obstructions. 3. Push the tube into the fitting until it snaps in place. 4. Pull on the connection to make sure the fitting is secure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4335 Fuel Line Coupler: Service and Repair Push Connect Fittings Fuel Line Removal Tool DISCONNECT WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Perform the fuel pressure release procedure. 2. Disconnect the safety clip from the male hose. 3. Install the fuel line disconnect tool and push into the fitting. 4. Separate the fittings. - Inspect for damage. - Clean the fittings. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4336 CONNECT 1. Align and push the tube into the fitting until you hear a click. NOTE: Lubricate the tube end with clean engine oil meeting Ford specification WSS-M2C153-F to ease assembly. 2. Pull on the fitting to make sure it is fully engaged, then install safety clip. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4337 Fuel Line Coupler: Service and Repair Spring Lock Couplings Disconnect Tool (3/8 Inch) 310-D004(D87L-9280) Disconnect Tool (1/2 Inch) DISCONNECT WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Perform the fuel pressure release procedure. 2. Remove the fuel tube clip. 3. Install the disconnect tool. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4338 4. Close and push the disconnect tool into the open side of the cage. 5. Separate the fitting. 6. Remove the disconnect tool. CONNECT 1. Connect the fitting. - Inspect and clean both the coupling ends. - Lubricate the O-rings with clean engine oil meeting Ford specification WSS-M2C153-F. - Connect the fitting. - Pull on the fitting to make sure it is fully engaged. - Install the safety clip. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair Fuel Pressure Regulator: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. - BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. 1. Perform the pre-service procedures. 2. Disconnect the battery ground cable. 3. Remove the engine cover. 4. Remove the fuel pressure regulator. 1. Disconnect the vacuum hose. 2. Remove the screws. 3. Remove the fuel pressure regulator. 5. Remove and discard the (A) fuel pressure regulator O-rings and the (B) seal. INSTALLATION 1. Follow the removal procedure in reverse order. NOTE: Lubricate the new O-rings with engine oil. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service and Repair Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. - BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. 1. Perform the pre-service procedures. 2. Disconnect the battery ground cable. 3. Remove the (B) fuel pressure relief valve from the (A) fuel injection supply manifold. INSTALLATION 1. Install the fuel pressure relief valve and tighten. 2. Connect the battery ground cable. 3. Perform the post-service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service and Repair Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. - BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. 1. Perform the pre-service procedures. 2. Disconnect the battery ground cable. 3. Remove the (B) fuel pressure relief valve from the (A) fuel injection supply manifold. INSTALLATION 1. Install the fuel pressure relief valve and tighten. 2. Connect the battery ground cable. 3. Perform the post-service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4353 Engine Compartment Fuse Box (Part 1 Of 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4354 Engine Compartment Fuse Box (Part 2 Of 2) The Fuel Pump Relay is located in the LH front of engine compartment, in engine compartment fuse box Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4357 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4358 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4359 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds Fuel Rail: Customer Interest Compuvalve - Rough Idle Speed/Stalls at Idle Speeds Article No. 00-10-4 05/15/00 ^ IDLE - ROUGH IDLE SPEED - BI-FUEL VEHICLES ONLY ^ STALL - DURING IDLE SPEEDS - BI-FUEL VEHICLES ONLY FORD: 1998-1999 E-250, E-350, F-150, F-250 LD ISSUE On some vehicles vaporizers with GFI model numbers Z5-1OO or Z7-1OO, may experience internal component deterioration due to fuel contamination. ACTION The following procedures are provided to expedite diagnostics and to determine if component debris (caused by fuel contamination) has impeded the operation of the Vaporizer, Compuvalve, Fuel Rails, and/or Injector Sleeves. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform all preliminary diagnostics as indicated in the Workshop Manual/Workshop information CD to ensure that the base vehicle is operational. Even a weak ignition system may cause a driveability concern in ALT fuel while not affecting gasoline. Use the NGS to verify that the PCM calibration matches the current bi-fuel calibration code in the following Calibration Chart. Confirm and record the model number of the vaporizer for the vehicle. On the F-Series truck, a mirror can be used to read the model number and on the Econoline van, unbolt the vaporizer from the bracket to read the model number. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4372 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4373 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4374 If the Vaporizer model number is not labeled Z5-1OO or Z7-1OO follow the procedures outlined in the Workshop Manual/Workshop information CD. If the Vaporizer model number is labeled Z5-1OO or Z7-1OO, continue with the following service procedure (Figures 1-3). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4375 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 603300, 607000, 607400, 608000, 608400, 609000, 609400 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds Fuel Rail: All Technical Service Bulletins Compuvalve - Rough Idle Speed/Stalls at Idle Speeds Article No. 00-10-4 05/15/00 ^ IDLE - ROUGH IDLE SPEED - BI-FUEL VEHICLES ONLY ^ STALL - DURING IDLE SPEEDS - BI-FUEL VEHICLES ONLY FORD: 1998-1999 E-250, E-350, F-150, F-250 LD ISSUE On some vehicles vaporizers with GFI model numbers Z5-1OO or Z7-1OO, may experience internal component deterioration due to fuel contamination. ACTION The following procedures are provided to expedite diagnostics and to determine if component debris (caused by fuel contamination) has impeded the operation of the Vaporizer, Compuvalve, Fuel Rails, and/or Injector Sleeves. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform all preliminary diagnostics as indicated in the Workshop Manual/Workshop information CD to ensure that the base vehicle is operational. Even a weak ignition system may cause a driveability concern in ALT fuel while not affecting gasoline. Use the NGS to verify that the PCM calibration matches the current bi-fuel calibration code in the following Calibration Chart. Confirm and record the model number of the vaporizer for the vehicle. On the F-Series truck, a mirror can be used to read the model number and on the Econoline van, unbolt the vaporizer from the bracket to read the model number. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4381 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4382 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4383 If the Vaporizer model number is not labeled Z5-1OO or Z7-1OO follow the procedures outlined in the Workshop Manual/Workshop information CD. If the Vaporizer model number is labeled Z5-1OO or Z7-1OO, continue with the following service procedure (Figures 1-3). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4384 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 603300, 607000, 607400, 608000, 608400, 609000, 609400 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4385 Fuel Rail: Service and Repair Spring Lock Coupling Disconnect Tool (3/8 - Inch) Spring Lock Coupling Disconnect Tool 1/2 (Inch) REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. - BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. 1. Perform the pre-service procedures. 2. Disconnect the battery ground cable. 3. Remove the engine cover. 4. Disconnect the fuel pressure regulator vacuum hose. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4386 5. Remove the fuel line tether clamps. 6. Using the (A) and (B) Spring Lock Coupling Disconnect Tools, disconnect the fuel lines. 7. Remove and discard the fuel line O-rings. 8. Disconnect the five RH fuel injector electrical connectors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4387 9. Disconnect the five LH fuel injector electrical connectors. 10. Remove the crankcase vent connector and hose. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4388 11. Disconnect the Exhaust Gas Recirculation (EGR) components. 1. Loosen the EGR valve to exhaust manifold lower fitting. 2. At the (A) EGR valve fitting, disconnect the EGR valve from the (B) EGR valve to exhaust manifold tube. 3. Disconnect the EGR transducer hoses. 4. Disconnect the EGR valve vacuum hose. 12. Disconnect the vapor management valve hose. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4389 13. Remove the bolts retaining the fuel injection supply manifold. 14. Lift the (A) fuel injection supply manifold and remove the (B) fuel injectors. 15. Remove and discard the O-rings from each fuel injector. 16. Shift and remove the fuel injection supply manifold. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4390 INSTALLATION 1. Follow the removal procedure in reverse order. NOTE: Lubricate the new O-rings with engine oil. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Tools and Equipment Fuel Supply Line: Tools and Equipment 3/8" Fuel Line Remover AST tool# 8013 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Tools and Equipment > Page 4394 Used for removing 3/8" fuel lines and feed lines from the fuel pump-sending unit. - For R and R of Fuel and Feed Lines - Quick line removal - Gold-Anodized Aluminum Construction - See Application Chart - Included in the 8100, 8107 and #8110 Line Disconnect Sets. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Tool is also available in the following kits: 8110 - 10-Pc. Line Disconnect Set Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Tools and Equipment > Page 4395 8107 - 7-Piece Line Disconnect Set Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4405 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4406 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4407 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4408 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4409 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4415 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4416 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4417 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4418 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4419 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4428 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4429 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4430 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4431 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4432 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4438 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4439 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4440 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4441 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4442 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations Full Body Views The Fuel Tank Temperature Sensor is located under LH center of vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Service and Repair Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly and the throttle body splash guard. 3. Remove the engine cover. 4. Disconnect the wiring and air hose at the Idle Air Control valve (IAC valve). 5. Remove the retaining bolts and idle air control valve. Discard the gasket. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Inertia Fuel Shutoff Switch: Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4452 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4453 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. The IFS 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. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4457 Engine Compartment Fuse Box (Part 2 Of 2) The PCM Power Relay is located at LH front of engine compartment, in engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 4463 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4467 Engine Compartment Fuse Box (Part 1 Of 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4468 Engine Compartment Fuse Box (Part 2 Of 2) The Fuel Pump Relay is located in the LH front of engine compartment, in engine compartment fuse box Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4471 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4472 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4473 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4474 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4475 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4476 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4477 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 4481 Engine Compartment Fuse Box (Part 2 Of 2) The PCM Power Relay is located at LH front of engine compartment, in engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Resonator, Intake Air > Component Information > Service and Repair Resonator: Service and Repair REMOVAL 1. Remove the screw retaining the intake air resonator. 2. Loosen the hose clamp at the resonator port. 3. Remove the engine intake air resonator. INSTALLATION 1. Follow the removal procedure in reverse order. 2. Tighten screw to 1.6-2.2 Nm (15-19 lb/in). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4494 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4495 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4501 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4502 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder Ignition Lock: All Technical Service Bulletins Ignition Key - Hard To Remove From Ignition Cylinder Article No. 99-16-4 08/09/99 ^ IGNITION KEY - HARD TO REMOVE FROM IGNITION CYLINDER ^ IGNITION KEY - HARD TO TURN FORD: 1992-1999 ECONOLINE 1997-1999 EXPEDITION, F-150, F-25C 1999 SUPER DUTY F SERIES LINCOLN: 1998-1999 NAVIGATOR This TSB article is being republished in its entirety to add vehicles covered by this TSB. ISSUE A hard to turn ignition key, and/or a hard to remove key from ignition cylinder may occur on some vehicles. This may be caused by a misaligned shift column shaft bushing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 4508 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 4509 ACTION A diagnostic and repair procedure has been developed to correctly repair the concern. Refer to the following Figures 1 through 3 for details. PART NUMBER PART NAME F3TZ-7L278-A Shift Column Shaft Bushing OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-5-9 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991604A Replace Ignition Lock 0.4 Hr. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 4510 Cylinder 991604B Replace Bushings 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7335 42 OASIS CODES: 112000, 602300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 4516 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 4517 ACTION A diagnostic and repair procedure has been developed to correctly repair the concern. Refer to the following Figures 1 through 3 for details. PART NUMBER PART NAME F3TZ-7L278-A Shift Column Shaft Bushing OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-5-9 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991604A Replace Ignition Lock 0.4 Hr. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 4518 Cylinder 991604B Replace Bushings 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7335 42 OASIS CODES: 112000, 602300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4519 Air Flow Meter/Sensor: Locations Engine Compartment Views The Mass Air Flow Sensor is located at the center of the engine compartment. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4520 Air Flow Meter/Sensor: Service and Repair 1. Disconnect the battery ground cable. NOTE: The sensing element located inside the Mass Air Flow sensor (MAF sensor) can be damaged by touching. 2. Remove the air cleaner assembly. 3. Separate the two halves of the air cleaner housing. 4. Disconnect the wiring connector from housing. 5. Remove the mounting plate and mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Full Body Views The Fuel Tank Temperature Sensor is located under LH center of vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Inertia Fuel Shutoff Switch: Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 4527 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 4528 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. The IFS 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. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 4532 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 4533 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly and throttle body splash shield. 3. Disconnect the wiring at the Throttle Position sensor (TP sensor). 4. Remove the retaining screws and sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair Throttle Body: Service and Repair REMOVAL WARNING: - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. - BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. 1. Disconnect the battery ground cable. 2. Remove the engine cover. 3. Remove the engine air cleaner assembly and the air cleaner outlet tube. 4. Remove the accelerator cable splash shield. 5. Disconnect the throttle body control linkage by disconnecting the (A) accelerator cable, the (B) speed control actuator cable and the (C) throttle control return spring. 6. Remove (A) bolts retaining the (B) accelerator cable bracket to the throttle body. Remove the throttle return spring from the (C) throttle bell crank. Remove the accelerator cable bracket. 7. Disconnect the Throttle Position sensor (TP sensor) connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Page 4537 8. Remove the throttle body. 1. Remove the four bolts. 2. Remove and discard the Throttle Body gasket (TB gasket). INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Throttle Cable/Linkage: Specifications Accelerator Pedal and Shaft Bolts .................................................................................................................................................... 22-28 Nm (16-21 Lb/Ft) Accelerator Cable Bracket Bolts ...................................................................................................................................................... 9-12 Nm (80-106 Lb/In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 4541 Throttle Cable/Linkage: Description and Operation The throttle is controlled by an accelerator cable attached to the accelerator pedal and shaft. The accelerator pedal and shaft should travel smoothly from the idle to the wide open throttle positions. Hesitation on return or prevention of return to the idle position must not occur. Surrounding components such as wiring, hoses, sound insulator and floor carpet must not contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft. The throttle assembly is not adjustable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Throttle Cable/Linkage: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the acceleration control system to duplicate the condition. 2. Inspect to determine if any of the following mechanical concerns apply. Visual Inspection Chart Mechanical - Damage accelerator pedal and shaft. - Damaged linkage. - Damaged accelerator cable. - High engine idle speed. - Damaged throttle body. 3. If the inspection reveals an obvious concern that can be readily identified, repair it as required. 4. If the concern remains after the inspection, determine the symptom(s) and go to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4544 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Page 4545 Throttle Cable/Linkage: Service and Repair REMOVAL 1. Hold the accelerator pedal in place and disconnect the accelerator cable from the accelerator pedal and shaft. 2. Remove the engine Air Cleaner (ACL) and outlet tube. 3. Depress the tab and remove the accelerator control splash shield. 4. Remove the accelerator cable from the bulkhead. From inside the vehicle, compress the retaining tabs on the cable end and remove the cable from the bulkhead. 5. Remove the accelerator cable from the throttle body cam. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Page 4546 6. Remove the accelerator cable from the clip. 7. Remove the accelerator cable from the accelerator cable bracket. Compress the retaining tabs on the cable and remove the accelerator cable from the bracket. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4550 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4551 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly and throttle body splash shield. 3. Disconnect the wiring at the Throttle Position sensor (TP sensor). 4. Remove the retaining screws and sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order: 1-6-5-10-2-7-3-8-4-9 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4568 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4569 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4570 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4571 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4572 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4573 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4574 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4575 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4576 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4577 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4578 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4579 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4580 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: All Technical Service Bulletins Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 4586 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 4587 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-23-11 > Nov > 99 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-23-11 > Nov > 99 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4597 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-23-11 > Nov > 99 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4598 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-23-11 > Nov > 99 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4599 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-23-11 > Nov > 99 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4600 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-23-11 > Nov > 99 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4601 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-23-11 > Nov > 99 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4602 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-23-11 > Nov > 99 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4603 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-23-11 > Nov > 99 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4604 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-23-11 > Nov > 99 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4605 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-23-11 > Nov > 99 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4606 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-23-11 > Nov > 99 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4607 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-23-11 > Nov > 99 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4608 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-23-11 > Nov > 99 > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4609 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4615 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4616 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4617 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4618 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4619 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4620 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4621 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4622 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4623 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4624 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4625 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4626 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4627 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4628 Keyless Entry Module: Locations Full Body Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4629 The Remote Keyless Entry (RKE) module with integral receiver is located behind the B-pillar on the driver side. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4630 Keyless Entry Module: Diagrams Remote Keyless Entry Module (C335) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4631 Remote Keyless Entry Module (C336) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4632 Keyless Entry Module: Description and Operation The Remote Keyless Entry (RKE) module performs the following functions: - Unlocks the driver front door. - Unlocks all doors. - Locks all doors. - Turns on the interior lamps after either front door handle is lifted. - Turns on the interior lamps when using a keyless entry remote transmitter. - Activates and deactivates a personal security panic alarm feature that sounds the horn and flashes the parking lamps and headlamps. - Activates the lock verify feature that sounds the horn when the lock button is pressed on the keyless entry remote transmitter twice within five seconds. - Remembers to lock the sliding door if the door locks are activated when the sliding door is open. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications TORQUE SPECIFICATIONS Crankshaft Position Sensor Bolt ............................................................................................................................................. 8-12 Nm (71-106 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4636 Crankshaft Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4637 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4638 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Release tension on the accessory drive belt. 4. Position the A/C compressor aside. NOTE: Do not remove the lines from the A/C compressor. 5. Disconnect the wiring at the sensor. 6. Remove the CKP sensor bolt and the Crankshaft Position sensor (CKP sensor). NOTE: The crankshaft pulley is shown removed for clarity. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4647 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4648 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4649 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4650 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4651 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4652 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4653 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4654 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4655 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4656 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4657 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4658 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4659 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4665 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4666 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4667 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4668 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4669 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4670 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4671 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4672 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4673 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4674 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4675 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4676 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4677 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips Ignition Coil: Technical Service Bulletins Ignition System - Coil-On-Plug Misfire Diagnostic Tips TSB 05-22-8 11/14/05 WDS COP KIT DIAGNOSTIC TIPS - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING FORD: 1996-1999 Taurus SHO 1998-2006 Crown Victoria, Mustang 2000 Taurus 2002-2005 Thunderbird 2003-2006 Focus 2004-2006 Taurus 2005-2006 Five Hundred, Freestyle 1997-2006 E-Series, Expedition, F-150 1999-2006 F-Super Duty 2000-2005 Excursion, F-53 2001-2006 Escape 2002-2005 Explorer 2005-2006 Escape Hybrid LINCOLN: 1997-1998 Mark VIII 1998-2002 Continental 1998-2006 Town Car 2000-2006 LS 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1998-2006 Grand Marquis 2000 Sable 2004-2005 Sable 2005-2006 Montego 2002-2005 Mountaineer 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 04-16-01 to update the vehicle applications and model years. NOTE FOLLOW THIS TSB PROCEDURE ONLY IF THERE ARE NO SPECIFIC MISFIRE TSBs/SSMs RELEASED FOR THE VEHICLE SYMPTOM BEING EXPERIENCED. ISSUE Approximately 50% of coil on plug (COP) coils returned for warranty do not have a problem. ACTION The misfiring cylinder must be identified through Self-Test misfire codes or through WDS Power Balance. Rule out base engine problems, rule out fuel problems, and then look at ignition problems (be sure to rule out coil primary circuit issues). Once the above steps have been completed, and the issue is in the secondary part of the ignition system, the oscilloscope procedure outlined in this TSB can isolate the difference between a coil or spark plug problem. SERVICE PROCEDURE The optional WDS COP Kit available through Rotunda will provide more accurate diagnosis and help reduce replacement of non-defective parts. The Kit (418-F5528) can be purchased through 1-800-ROTUNDA. The following material will detail the diagnostic steps on WDS to take the guesswork out of misfire diagnosis using the COP Kit. The following procedure is for cylinder specific misfires and not random misfires. Random misfires have a different root cause and are not covered by this TSB. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4682 Misfire Definition: A misfiring cylinder is lacking power relative to the other cylinders. The causes for a cylinder specific misfire could be fuel, spark, or mechanical problems. Perform a thorough visual inspection. If no visible concerns are found use the following WDS tools for misfire diagnosis: ^ Self-test (Check for codes first) Power Balance (Identify the cylinder of concern) ^ Relative Compression (Rule out a possible mechanical issue) ^ Fuel (Make sure fuel injectors are not restricted) ^ Ignition (Make sure spark plugs and coils are working properly) ^ Oscilloscope (Detailed signal analysis) NOTE USE THE ENCYCLOPEDIA BUTTON IN THE LOWER LEFT CORNER OF THE SCREEN FOR DETAILED INFORMATION ON THE WDS TOOL BEING DISPLAYED. If there is a self-test code identifying a particular cylinder then you just need to determine if it is a fuel, ignition, or possibly a mechanical problem. Proceed to Step 2 after running Relative Compression to rule out any mechanical issues. If there is no self-test code and the customer concern is a miss, proceed to Step 1. Step 1: (Select Toolbox Icon, then Powertrain, then Power Balance) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4683 The cylinder specific miss has to be identified as shown in the example in Figure 2 in order to proceed with the remaining steps. If the miss does not occur at idle (in the bay), try to brake torque the engine. This extra loading should reproduce the miss in the bay. If the miss cannot be reproduced during brake torque, select Relative Compression under Powertrain on WDS before going on a road test to rule out mechanical problems. If Relative Compression shows a problem then the base engine issue must be serviced. If Relative Compression results are good (Figure 3), road test under as many different driving conditions as possible until the miss occurs on Power Balance. Some misses may be very intermiffent so be patient and concentrate on steady load conditions. Once a cylinder dropout is identified proceed to Step 2. Step 2: (Select Toolbox Icon, then Powertrain, then Fuel System Test) Run Fuel System Test on WDS to determine if there may be a fuel problem. After completing fuel Pressure/Leakdown test, select Injector flow to isolate Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4684 a restricted injector as shown in Figure 4. If all the injectors are within specification, proceed to Step 3. Step 3: (Select Toolbox Icon, then Powertrain, then Ignition System Test) Run Ignition System Test on WDS to determine if there is an ignition problem. Look at both duration (DUR) and kilovolts (KV) and look for values that standout from the rest as shown in Figure 5 and Figure 6. NOTE LIVE DISPLAY HAS TO AVERAGE IGNITION VALUES BECAUSE THERE IS TOO MUCH DATA TO DISPLAY. MAKE A CAPTURE TO VIEW EACH ENGINE EVENT WITHOUT AVERAGING. THIS CAN BE HELPFUL WHEN THE PROBLEM IS INTERMITTENT. IF THE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4685 MISS IS EXTREMELY INTERMITTENT AND DOES NOT SHOW UP IN IGNITION, PROCEED TO STEP 4. If either spark duration or peak KV on the Red Probe (Suspect Cylinder) are offset from the values displayed on the Black Probe (Known Good Cylinder) then the problem is in the ignition system. Rule out coil primary circuit issues before proceeding to coil secondary issues such as the spark plug , coil boot, or possibly the coil. Use the WDS Oscilloscope with the COP kit to determine if the issue is the coil or the spark plug. Step 4: (Select Toolbox, then Oscilloscope) WARNING SECONDARY IGNITION VOLTAGES ARE VERY HIGH. KEEP HANDS AND TOOLS AWAY FROM THE END OF THE COIL THAT SUPPLIES THE SPARK. SET-UP: With the engine off, pull the suspect coil from the cylinder well and turn it upside down so the coil cannot spark to any other surface as shown in Figure 1. Wrap a clean shop cloth around the hard shell of the coil to help keep the coil propped up and stable. CAUTION THE COIL BOOT CAN BE DAMAGED IF THE COIL SPARKS TO ANOTHER SURFACE DURING THIS PROCEDURE. Keep the coil connected to the harness and leave the WDS COP clip attached to the coil. Route the coil clip wire and cable away from the coil being tested as well as other coils to avoid noise interference. Disconnect the injector of the cylinder being tested so raw fuel is not washing the cylinder. This is a stress test for the coil. The type of waveform displayed on the oscilloscope will show whether a coil or the plug is the problem if all previous steps have been followed. Keep hands and tools away from the end of the coil that supplies the spark. COP Stress Test Procedure: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4686 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4687 Go to the Oscilloscope Tool and select Channel 3, then select Auto, then select COP_STRESS_TEST_RED. This pre-configured setting will zoom-in on the peak firing of the coil being tested. Start the engine and be sure the coil is not sparking to any surface. If the coil is sparking to other surfaces, turn the engine off immediately and readjust the coil so it cannot spark to any other surface. Restart the engine and touch the Red Man icon to start the oscilloscope. All settings are pre-configured and no adjustments are necessary. Compare the waveform you get with the examples provided in Figures 7, 8, and 9). Figure 7 is a good waveform. If your waveform is similar to Figure 7 the coil is working correctly. Suspect the spark plug. Figure 8 and Figure 9 are examples of problem coils. Replace the coil if the waveform is similar to Figures 8 or 9. The coil is causing the misfire when the peak firing appears like those shown in Figures 8 and 9. Notice the difference in the peak-firing signal when compared to the good peak signal in Figure 7. Figure 9 shows a more dramatic fault in the peak failure. Most root causes of misfire issues can be identified quickly using the steps outlined above. Some misfire issues can be difficult making the oscilloscope an important part of your diagnostic toolbox. OTHER APPLICABLE ARTICLES: 05-13-4 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 4688 Ignition Coil: Specifications Ignition Coil Bolts ................................................................................................................................. ............................................... 5-7 Nm (44-62 Lb/In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 4689 Ignition Coil: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 4690 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 4691 Ignition Coil: Service and Repair REMOVAL 1. Remove the engine cover. 2. Remove the air cleaner assembly. 3. Disconnect the wiring at the coil. 4. Remove the screw and the coil. INSTALLATION NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A meeting Ford specification ESE-M1C171-A or equivalent to the inside of the coil boots. 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4695 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4696 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Remove the Knock Sensor (KS). 1. Disconnect the electrical connector. 2. Remove the knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4706 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4707 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4708 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4709 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4710 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4711 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4712 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4713 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4714 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4715 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4716 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4717 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4718 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4724 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4725 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4726 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4727 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4728 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4729 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4730 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4731 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4732 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4733 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4734 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4735 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4736 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4737 Camshaft Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4738 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4739 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. The 4.6L Engine Is Shown; 5.4L And 6.8L Are Similar 2. Remove the Camshaft Position sensor (CMP sensor). 1. Disconnect the electrical connector. 2. Remove the bolt. 3. Remove the CMP sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications TORQUE SPECIFICATIONS Crankshaft Position Sensor Bolt ............................................................................................................................................. 8-12 Nm (71-106 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4743 Crankshaft Position Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4744 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4745 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Release tension on the accessory drive belt. 4. Position the A/C compressor aside. NOTE: Do not remove the lines from the A/C compressor. 5. Disconnect the wiring at the sensor. 6. Remove the CKP sensor bolt and the Crankshaft Position sensor (CKP sensor). NOTE: The crankshaft pulley is shown removed for clarity. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4754 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4755 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4756 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4757 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4758 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4759 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4760 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4761 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4762 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4763 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4764 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4765 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4766 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Heat Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 4772 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 4773 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 98-20-10 > Oct > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 98-20-10 > Oct > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4783 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 98-20-10 > Oct > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4784 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 98-20-10 > Oct > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4785 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 98-20-10 > Oct > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4786 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 98-20-10 > Oct > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4787 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 98-20-10 > Oct > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4788 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 98-20-10 > Oct > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4789 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 98-20-10 > Oct > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4790 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 98-20-10 > Oct > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4791 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 98-20-10 > Oct > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4792 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 98-20-10 > Oct > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4793 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 98-20-10 > Oct > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4794 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 98-20-10 > Oct > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4795 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heat Shield: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heat Shield: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4801 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heat Shield: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4802 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heat Shield: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4803 DISCLAIMER Service Procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heat Shield: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4804 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heat Shield: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4805 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heat Shield: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4806 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heat Shield: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4807 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heat Shield: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4808 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heat Shield: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4809 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heat Shield: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4810 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heat Shield: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4811 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heat Shield: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4812 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heat Shield: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4813 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4819 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4820 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4821 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4822 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4823 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4824 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Replacement, Functional Ignition Switch Lock Cylinder: Service and Repair Replacement, Functional REMOVAL NOTE: The following procedure applies to vehicles that have functional lock cylinders and keys. If key numbers are known, the proper key can be made. 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Position the lock cylinder to RUN. (2) Using a suitable tool, push upward on the cylinder release tab through the hole in the lower shroud while pulling the cylinder outward. INSTALLATION 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Replacement, Functional > Page 4827 Ignition Switch Lock Cylinder: Service and Repair Replacement, Non-Functional REMOVAL NOTE: The following procedure applies to vehicles in which the ignition lock is inoperative and the lock cylinder cannot be rotated due to a lost or broken key, unknown key number, or a cap that has been damaged or broken to the extent that the lock cylinder cannot be rotated. 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 1/8 inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8 inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Replacement, Functional > Page 4828 6. Remove the bearing and the gear. - Thoroughly clean all drill shavings from the steering column and inspect it for damage. INSTALLATION 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. NOTE: Use a new ignition switch lock cylinder. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4832 Engine Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4833 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Remove the Knock Sensor (KS). 1. Disconnect the electrical connector. 2. Remove the knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark Plug Gap ................................................................................................................................... ................................... 1.32-1.42 mm (0.052-0.056 in) Spark Plug Torque ......................................... ....................................................................................................................................... 9-20 Nm (7-14 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap > Page 4838 Spark Plug: Specifications Torque Spark Plug Gap ................................................................................................................................... ................................... 1.32-1.42 mm (0.052-0.056 in) Spark Plug Torque ......................................... ....................................................................................................................................... 9-20 Nm (7-14 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4839 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................ AWSF22E Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4840 Spark Plug: Service and Repair REMOVAL CAUTION: Mark spark plug locations and return to original location. 1. Remove the ignition coil. 2. Remove the spark plug. 3. Inspect the spark plugs; replace if required. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications TORQUE SPECIFICATIONS Brake Shift Interlock Solenoid Bolts ........................................................................................................................................ 7-11 Nm (62-97 inch lbs.) Shift Lock Actuator Bolts ......................................................................................................................................................... 7-11 Nm (62-97 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4847 Shift Interlock Solenoid: Service and Repair REMOVAL 1. Disconnect the battery. WARNING: ON VEHICLES EQUIPPED WITH AN AUXILIARY BATTERY, BOTH THE NEGATIVE AND POSITIVE BATTERY CABLES MUST BE DISCONNECTED. WARNING: ON VEHICLES EQUIPPED WITH A 7.3L, ENGINE, BOTH THE PRIMARY AND SECONDARY BATTERIES MUST BE DISCONNECTED. 2. Remove the instrument panel steering column cover, the driver side knee brace and the instrument panel steering column opening cover reinforcement. 3. Disconnect all necessary harness connectors and separate the harness bracket from the steering column. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4848 4. Remove the shift indicator cable and position it aside. 5. Remove the nuts and lower the steering column. 6. Remove the shift lock actuator and disconnect the harness connector. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4849 1. Follow the removal procedure in reverse order. 2. Make sure the shift cable and the shift indicator cable are properly adjusted. Verify shift lock actuator operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection For testing procedures for the Transmission Control Indicator Lamp (TCIL), please refer to Pinpoint Test C in Automatic Transmission/Transaxle / Testing and Inspection / Procedures / External Control Diagnostics. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 1. Place the transmission range selector lever into MANUAL 1 position, then back to the (D) position. 2. Hang a three-pound weight on the transmission range selector lever. 3. Center the pointer in the middle of the (D) position. - Rotate the thumb wheel, located on the bottom of the steering column, to adjust the pointer. 4. Remove the weight. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Description and Operation Overdrive Switch: Description and Operation The Transmission Control Switch (TCS) and Transmission Control Indicator Lamp (TCIL) are located inside the end of the gearshift lever. Pushing the TCS will either disengage or engage the overdrive function of the transmission. When overdrive is disengaged, the TCIL will illuminate the word OFF. Each time the ignition switch is placed in the RUN position, the transmission will automatically provide overdrive operation regardless of TCS position the last time the vehicle was running. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Description and Operation > Page 4863 Overdrive Switch: Testing and Inspection For testing procedures for the Transmission Control Switch (TCS), please refer to Pinpoint Test C in Automatic Transmission/Transaxle / Testing and Inspection / Procedures / External Control Diagnostics. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Mode Switch: Service and Repair TRANSMISSION MODE SWITCH REMOVAL 1. Remove the Transmission Control (TC) switch. 1. Remove the TC switch cover. 2. Remove the TC switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor .............................................................................................................................................. 8-10 Nm (75-85 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 4870 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 4871 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 4872 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 4873 Transmission Position Switch/Sensor: Service and Repair Special Tools REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1. Remove the bolts. 2. Remove the sensor. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 4874 1. Install the digital transmission range (TR) sensor. 1. Install the sensor. 2. Loosely install the bolts. 2. Install the Digital Transmission Range (TR) Sensor Alignment Tool. NOTE: Make sure that the manual control lever is in the neutral position. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 4875 5. Reconnect the connector. 6. Reconnect the battery ground cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Sensor Transmission Speed Sensor: Locations Output Shaft Speed Sensor Transmission View The Output Shaft Speed Sensor is located under the vehicle, on left side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Sensor > Page 4880 Transmission Speed Sensor: Locations Turbine Speed Sensor The Turbine Shaft Speed Sensor is located under the vehicle, on right side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Page 4881 Output Shaft Speed Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 98-7-10 > Apr > 98 > A/T - E4OD Harsh 1-2 Shift On Light Throttle PROM - Programmable Read Only Memory: Customer Interest A/T - E4OD Harsh 1-2 Shift On Light Throttle Article No. 98-7-10 04/13/98 TRANSMISSION - E4OD-HARSH 1-2 SHIFT AT LIGHT THROTTLE - VEHICLES EQUIPPED WITH 5.4L OR 6.8L ENGINE - VEHICLES BUILT THROUGH 1/12/98 LIGHT TRUCK: 1997-98 ECONOLINE This TSB article is being republished in its entirety to revise the Service Procedure. CALIBRATION: 7-46K-R06, 7-46O-R06, 7-74C-R07, 7-74S-R07, 7-74T-R07, 7-74U-R06, 7-74V-R06, 7-96E-R06, 7-96T-R10, 7-96W-R06, 7-96X-R06, 8-46K-R05, 8-46Q-R05, 8-74C-R05, 8-74S-R05, 8-74T-R05, 8-74U-R05, 8-74V-R05, 8-96E-R05, 8-96T-R05, 8-96W-R05, 8-96X-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: Some vehicles may experience a harsh 1-2 shift while driving under light throttle conditions. This may be caused by the Powertrain Control Module (PCM) calibration. ACTION: Reprogram the PCM. The revised calibration should reduce engine torque during the 1-2 shift to help improve the 1-2 shift feel. Refer to the Recalibration Cross Reference Chart for correct PCM calibration usage. NOTE: 1997 ECONOLINE BUILT BEFORE 8/16/97 AND EQUIPPED WITH 5.4L ENGINE: ALSO INSTALL NEW INTERMEDIATE CLUTCH FRICTION PLATES (F75Z-7B164-SA) AND ACCUMULATOR (F6TZ-7G422-B) AND REPROGRAM THE PCM. Perform normal diagnostics as outlined in the 1998 Econoline Workshop Manual and service as required. If the vehicle build date is before 1/12/98, and the concern is still present, reprogram the PCM. NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 98-7-10 > Apr > 98 > A/T - E4OD Harsh 1-2 Shift On Light Throttle > Page 4890 Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-4-23 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980710A Reprogram Powertrain 0.6 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 501000, 504000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4896 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4897 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 98-7-10 > Apr > 98 > A/T - E4OD Harsh 1-2 Shift On Light Throttle PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - E4OD Harsh 1-2 Shift On Light Throttle Article No. 98-7-10 04/13/98 TRANSMISSION - E4OD-HARSH 1-2 SHIFT AT LIGHT THROTTLE - VEHICLES EQUIPPED WITH 5.4L OR 6.8L ENGINE - VEHICLES BUILT THROUGH 1/12/98 LIGHT TRUCK: 1997-98 ECONOLINE This TSB article is being republished in its entirety to revise the Service Procedure. CALIBRATION: 7-46K-R06, 7-46O-R06, 7-74C-R07, 7-74S-R07, 7-74T-R07, 7-74U-R06, 7-74V-R06, 7-96E-R06, 7-96T-R10, 7-96W-R06, 7-96X-R06, 8-46K-R05, 8-46Q-R05, 8-74C-R05, 8-74S-R05, 8-74T-R05, 8-74U-R05, 8-74V-R05, 8-96E-R05, 8-96T-R05, 8-96W-R05, 8-96X-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: Some vehicles may experience a harsh 1-2 shift while driving under light throttle conditions. This may be caused by the Powertrain Control Module (PCM) calibration. ACTION: Reprogram the PCM. The revised calibration should reduce engine torque during the 1-2 shift to help improve the 1-2 shift feel. Refer to the Recalibration Cross Reference Chart for correct PCM calibration usage. NOTE: 1997 ECONOLINE BUILT BEFORE 8/16/97 AND EQUIPPED WITH 5.4L ENGINE: ALSO INSTALL NEW INTERMEDIATE CLUTCH FRICTION PLATES (F75Z-7B164-SA) AND ACCUMULATOR (F6TZ-7G422-B) AND REPROGRAM THE PCM. Perform normal diagnostics as outlined in the 1998 Econoline Workshop Manual and service as required. If the vehicle build date is before 1/12/98, and the concern is still present, reprogram the PCM. NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 98-7-10 > Apr > 98 > A/T - E4OD Harsh 1-2 Shift On Light Throttle > Page 4902 Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-4-23 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980710A Reprogram Powertrain 0.6 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 501000, 504000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4908 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4909 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications TORQUE SPECIFICATIONS Brake Shift Interlock Solenoid Bolts ........................................................................................................................................ 7-11 Nm (62-97 inch lbs.) Shift Lock Actuator Bolts ......................................................................................................................................................... 7-11 Nm (62-97 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4916 Shift Interlock Solenoid: Service and Repair REMOVAL 1. Disconnect the battery. WARNING: ON VEHICLES EQUIPPED WITH AN AUXILIARY BATTERY, BOTH THE NEGATIVE AND POSITIVE BATTERY CABLES MUST BE DISCONNECTED. WARNING: ON VEHICLES EQUIPPED WITH A 7.3L, ENGINE, BOTH THE PRIMARY AND SECONDARY BATTERIES MUST BE DISCONNECTED. 2. Remove the instrument panel steering column cover, the driver side knee brace and the instrument panel steering column opening cover reinforcement. 3. Disconnect all necessary harness connectors and separate the harness bracket from the steering column. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4917 4. Remove the shift indicator cable and position it aside. 5. Remove the nuts and lower the steering column. 6. Remove the shift lock actuator and disconnect the harness connector. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4918 1. Follow the removal procedure in reverse order. 2. Make sure the shift cable and the shift indicator cable are properly adjusted. Verify shift lock actuator operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications TORQUE SPECIFICATIONS Brake Shift Interlock Solenoid Bolts ........................................................................................................................................ 7-11 Nm (62-97 inch lbs.) Shift Lock Actuator Bolts ......................................................................................................................................................... 7-11 Nm (62-97 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4924 Shift Interlock Solenoid: Service and Repair REMOVAL 1. Disconnect the battery. WARNING: ON VEHICLES EQUIPPED WITH AN AUXILIARY BATTERY, BOTH THE NEGATIVE AND POSITIVE BATTERY CABLES MUST BE DISCONNECTED. WARNING: ON VEHICLES EQUIPPED WITH A 7.3L, ENGINE, BOTH THE PRIMARY AND SECONDARY BATTERIES MUST BE DISCONNECTED. 2. Remove the instrument panel steering column cover, the driver side knee brace and the instrument panel steering column opening cover reinforcement. 3. Disconnect all necessary harness connectors and separate the harness bracket from the steering column. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4925 4. Remove the shift indicator cable and position it aside. 5. Remove the nuts and lower the steering column. 6. Remove the shift lock actuator and disconnect the harness connector. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4926 1. Follow the removal procedure in reverse order. 2. Make sure the shift cable and the shift indicator cable are properly adjusted. Verify shift lock actuator operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Accumulator: Customer Interest A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Article No. 99-18-5 09/06/99 ^ TRANSMISSION CONTROL INDICATOR LAMP (TCIL) - TCIL ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) P0782 STORED IN MEMORY - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 AND WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 FORD: 1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1997-1998 MARK VIII 1997-1999 TOWN CAR MERCURY: 1997-1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking 2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782. ACTION Verify if delayed upshift is normal cold shift scheduling or a possible leak past the large diameter 2-3 accumulator seal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using New Generation Star (NGS) Tester, perform all self tests and record DTCs. 2. Monitor rpm, and gear command Parameter Identification Displays (PIDs) with the NGS Tester during the 2-3 shift. 3. If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS Tester, then vehicle has upshifted properly and no repair is necessary. If engine rpm does not drop within 1-2 seconds, continue to Step 4. 4. If engine rpm does not drop when the PCM commands third gear, then replace the 2-3 accumulator piston using the revised Accumulator Piston (F7AZ-7H292-AB). Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Accumulator Piston OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-1-3 WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991805A Replace Accumulator 1.8 Hrs. Piston Per Service Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 4935 Procedure (Includes Diagnosis) 991805B Diagnosis Only (Do Not 0.8 Hr. Use With Operation A) DEALER CODING CONDITION BASIC PART NO CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 99-9-6 > May > 99 > A/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift Accumulator: Customer Interest A/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift Article No. 99-9-6 05/17/99 FORD: 1994-1997 THUNDERBIRD 1995-1998 CROWN VICTORIA 1996-1998 MUSTANG LINCOLN-MERCURY: 1993-1998 MARK VIII 1994-1997 COUGAR 1995-1998 GRAND MARQUIS, TOWN CAR LIGHT TRUCK: 1994-1998 ECONOLINE, F-150 1996-1998 EXPLORER 1997-1998 EXPEDITION, F-25O LD, MOUNTAINEER This concern is ONLY for vehicles with Ford Quality Remanufactured (FQR) 4R70W Transmission Exchange Units With Julian build dates between 062-97 And 04099 (corresponding serial numbers are between R0475797 and R0771887). ISSUE A delayed or no 2-3 upshift, primarily when the transmission is cold, may be evident on some vehicles In some cases, Diagnostic Trouble Code (DTC) P0782 may also be present. This may be caused by fluid pressure leakage past the larger diameter seal of the 2-3 accumulator. ACTION Replace the 2-3 accumulator piston using a revised piston. The revised piston will increase seal/bore interference, eliminating any internal leak relating to the 2-3 accumulator piston reducing the possibility of 2-3 upshift concerns. Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Piston OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990906A Replace Accumulator 1.0 Hr. Piston DEALER CODING CONDITION BASIC PART NO. CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up Technical Service Bulletin # 98-20-9 Date: 981012 A/T - E4OD/4R100 Ticking Noise On Start Up Article No. 98-20-9 10/12/98 ^ NOISE - "TICKING" OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES WITH E4OD/4R100 TRANSMISSION AND BUILT THROUGH 6/11/98 ^ TRANSMISSION - E4OD/4R100 - "TICKING" NOISE OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES BUILT THROUGH 6/11/98 LIGHT TRUCK: 1998 ECONOLINE, EXPEDITION, F-150, F-250 LD, NAVIGATOR 1999 F-250 HD, F-350, SUPER DUTY F SERIES ISSUE A "ticking" noise on initial startup with shift selector in "P" or "N" position may occur on some vehicles. This may be caused by the overdrive clutch steel separator plate(s) impacting against the case internal spline. ACTION Replace the specified transmission components per the following Service Procedure. NOTE THE TICKING NOISE TYPICALLY IS ONLY PRESENT DURING INITIAL STARTUP AFTER THE VEHICLE HAS SOAKED LONG ENOUGH FOR THE TRANSMISSION FLUID TEMPERATURE TO REACH NEAR THE AMBIENT TEMPERATURE. THIS NOISE MAY BE HEARD INTERMITTENTLY DURING NORMAL OPERATING TEMPERATURES IN OTHER GEAR RANGES. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982009A Replace Specific 5.0 Hrs. Transmission Hardware F-Series LD 4X2 5.4L 982009B Replace Specific 6.8 Hrs. Transmission Hardware - F-Series LD 4X4 5.4L 982009C Replace Specific 5.0 Hrs. Transmission Hardware - Expedition/Navigator 4X2 5.4L 982009D Replace Specific 6.8 Hrs. Transmission Hardware - Expedition/Navigator 4X4 5.4L 982009E Extra Time To Adjust 0.4 Hr. Four-Wheel Air Suspension Ride Height - Expedition/Navigator Only 982009F Replace Specific 4.6 Hrs. Transmission Hardware - E-Series 5.4L or 6.8L Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up > Page 4944 982009G Replace Specific 4.1 Hrs. Transmission Hardware - E-Series 7.3L 982009H Replace Specific 3.9 Hrs. Transmission Hardware - F-Series HD 4X2 5.4L Or 6.8L 982009I Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 5.4L Or 6.8L 982009J Replace Specific 3.8 Hrs. Transmission Hardware - F-Series HD 4X2 7.3L 982009K Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 7.3L DEALER CODING CONDITION BASIC PART NO. CODE 7B164 07 7G422 07 OASIS CODES: 504000, 597997, 702000 Service Procedure 1. Verify vehicle's build date (Job # 1 built through 6/11/98). 2. Allow vehicle to soak long enough (possibly overnight) that the transmission fluid temperature is near the ambient temperature. Perform initial cold startup. 3. Verify ticking noise with the transmission shift selector in "P" (Park) and "N" (Neutral). 4. When ticking noise is confirmed, refer to the Transmission Hardware Application Chart to update transmission hardware as indicated by vehicle/engine application. NOTE FOLLOW ALL OF THE NORMAL SERVICE PROCEDURE AS OUTLINED IN THE APPROPRIATE WORKSHOP MANUAL. NOTE THE BUILD DATE LISTED MAY VARY SLIGHTLY FOR SOME VEHICLE APPLICATIONS. WHEN SERVICE IS REQUIRED ON A Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up > Page 4945 VEHICLE WITH THIS TICK CONCERN, IT IS RECOMMENDED THAT THE TRANSMISSION BE DISASSEMBLED DOWN TO AND INCLUDING THE COAST CLUTCH PRIOR TO PART ORDERING OR PURCHASE. THIS WILL ALLOW VERIFICATION OF THE CORRECT PARTS REQUIRED. INSPECT THE COAST CLUTCH WHEN REMOVED. IF THE COAST CLUTCH CYLINDER IS THE NEW DESIGN STAMPED, WELDED STEEL USE THE -BA LEVEL OVERDRIVE PLATES (REFER TO THE APPLICATION CHART). IF THE COAST CLUTCH CYLINDER IS THE PREVIOUS E4OD CAST IRON DESIGN USE THE -CA LEVEL OVERDRIVE PLATES AND ANY OTHER ASSOCIATED PARTS RECOMMENDED IN THE TRANSMISSION HARDWARE APPLICATION CHART. CAUTION MIXING COMPONENTS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. CAUTION USING COMPONENTS OTHER THAN AS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-18 > Oct > 06 > Restraints Air Bag Lamp ON/DTC's B1876/B1880/B1920 Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/DTC's B1876/B1880/B1920 TSB 06-21-18 10/30/06 DTC B1876, B1880, B1915 AND/OR B1920 IN THE ECS MODULE DUE TO HIGH CURRENT AFTERMARKET DEVICES FORD: 1997-2006 E-Series This article supersedes TSB 05-2-8 to update the vehicle model years. ISSUE Some vehicles with high-current aftermarket devices (such as motors for wheel chair lifts) operating at 75 amps or higher may cause electrical transients (voltage spikes), leading to damage of the airbag electronic crash sensor (ECS) module. If this occurs, the airbag lamp will turn on indicating a fault in the airbag system and diagnostic trouble codes (DTC) B1876, B1880, B1915 and/or B1920 will be present. ACTION Follow normal diagnostics per Workshop Manual, Section 501-20B. If pinpoint tests lead to replacement of the ECS module, and the vehicle does contain high-current aftermarket equipment, installation of an ECS module circuit protection improvement kit is recommended. This will prevent recurring damage to the new ECS module. SERVICE PROCEDURE Refer to the kit installation instructions. Cost of the protection kit and installation expenses are the responsibility of the modifier or customer. NOTE READ AND FOLLOW ALL WARNINGS LOCATED IN WORKSHOP MANUAL, SECTION 501-20B BEFORE PERFORMING ANY PROCEDURE OR TESTS ON THE RESTRAINTS SYSTEM. Parts Block WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accumulator: > 06-21-18 > Oct > 06 > Customer Interest for Accumulator: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Accumulator: Customer Interest A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Article No. 99-18-5 09/06/99 ^ TRANSMISSION CONTROL INDICATOR LAMP (TCIL) - TCIL ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) P0782 STORED IN MEMORY - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 AND WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 FORD: 1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1997-1998 MARK VIII 1997-1999 TOWN CAR MERCURY: 1997-1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking 2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782. ACTION Verify if delayed upshift is normal cold shift scheduling or a possible leak past the large diameter 2-3 accumulator seal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using New Generation Star (NGS) Tester, perform all self tests and record DTCs. 2. Monitor rpm, and gear command Parameter Identification Displays (PIDs) with the NGS Tester during the 2-3 shift. 3. If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS Tester, then vehicle has upshifted properly and no repair is necessary. If engine rpm does not drop within 1-2 seconds, continue to Step 4. 4. If engine rpm does not drop when the PCM commands third gear, then replace the 2-3 accumulator piston using the revised Accumulator Piston (F7AZ-7H292-AB). Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Accumulator Piston OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-1-3 WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991805A Replace Accumulator 1.8 Hrs. Piston Per Service Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accumulator: > 06-21-18 > Oct > 06 > Customer Interest for Accumulator: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 4960 Procedure (Includes Diagnosis) 991805B Diagnosis Only (Do Not 0.8 Hr. Use With Operation A) DEALER CODING CONDITION BASIC PART NO CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accumulator: > 06-21-18 > Oct > 06 > Customer Interest for Accumulator: > 99-9-6 > May > 99 > A/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift Accumulator: Customer Interest A/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift Article No. 99-9-6 05/17/99 FORD: 1994-1997 THUNDERBIRD 1995-1998 CROWN VICTORIA 1996-1998 MUSTANG LINCOLN-MERCURY: 1993-1998 MARK VIII 1994-1997 COUGAR 1995-1998 GRAND MARQUIS, TOWN CAR LIGHT TRUCK: 1994-1998 ECONOLINE, F-150 1996-1998 EXPLORER 1997-1998 EXPEDITION, F-25O LD, MOUNTAINEER This concern is ONLY for vehicles with Ford Quality Remanufactured (FQR) 4R70W Transmission Exchange Units With Julian build dates between 062-97 And 04099 (corresponding serial numbers are between R0475797 and R0771887). ISSUE A delayed or no 2-3 upshift, primarily when the transmission is cold, may be evident on some vehicles In some cases, Diagnostic Trouble Code (DTC) P0782 may also be present. This may be caused by fluid pressure leakage past the larger diameter seal of the 2-3 accumulator. ACTION Replace the 2-3 accumulator piston using a revised piston. The revised piston will increase seal/bore interference, eliminating any internal leak relating to the 2-3 accumulator piston reducing the possibility of 2-3 upshift concerns. Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Piston OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990906A Replace Accumulator 1.0 Hr. Piston DEALER CODING CONDITION BASIC PART NO. CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accumulator: > 06-21-18 > Oct > 06 > Customer Interest for Accumulator: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up Technical Service Bulletin # 98-20-9 Date: 981012 A/T - E4OD/4R100 Ticking Noise On Start Up Article No. 98-20-9 10/12/98 ^ NOISE - "TICKING" OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES WITH E4OD/4R100 TRANSMISSION AND BUILT THROUGH 6/11/98 ^ TRANSMISSION - E4OD/4R100 - "TICKING" NOISE OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES BUILT THROUGH 6/11/98 LIGHT TRUCK: 1998 ECONOLINE, EXPEDITION, F-150, F-250 LD, NAVIGATOR 1999 F-250 HD, F-350, SUPER DUTY F SERIES ISSUE A "ticking" noise on initial startup with shift selector in "P" or "N" position may occur on some vehicles. This may be caused by the overdrive clutch steel separator plate(s) impacting against the case internal spline. ACTION Replace the specified transmission components per the following Service Procedure. NOTE THE TICKING NOISE TYPICALLY IS ONLY PRESENT DURING INITIAL STARTUP AFTER THE VEHICLE HAS SOAKED LONG ENOUGH FOR THE TRANSMISSION FLUID TEMPERATURE TO REACH NEAR THE AMBIENT TEMPERATURE. THIS NOISE MAY BE HEARD INTERMITTENTLY DURING NORMAL OPERATING TEMPERATURES IN OTHER GEAR RANGES. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982009A Replace Specific 5.0 Hrs. Transmission Hardware F-Series LD 4X2 5.4L 982009B Replace Specific 6.8 Hrs. Transmission Hardware - F-Series LD 4X4 5.4L 982009C Replace Specific 5.0 Hrs. Transmission Hardware - Expedition/Navigator 4X2 5.4L 982009D Replace Specific 6.8 Hrs. Transmission Hardware - Expedition/Navigator 4X4 5.4L 982009E Extra Time To Adjust 0.4 Hr. Four-Wheel Air Suspension Ride Height - Expedition/Navigator Only 982009F Replace Specific 4.6 Hrs. Transmission Hardware - E-Series 5.4L or 6.8L Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accumulator: > 06-21-18 > Oct > 06 > Customer Interest for Accumulator: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up > Page 4969 982009G Replace Specific 4.1 Hrs. Transmission Hardware - E-Series 7.3L 982009H Replace Specific 3.9 Hrs. Transmission Hardware - F-Series HD 4X2 5.4L Or 6.8L 982009I Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 5.4L Or 6.8L 982009J Replace Specific 3.8 Hrs. Transmission Hardware - F-Series HD 4X2 7.3L 982009K Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 7.3L DEALER CODING CONDITION BASIC PART NO. CODE 7B164 07 7G422 07 OASIS CODES: 504000, 597997, 702000 Service Procedure 1. Verify vehicle's build date (Job # 1 built through 6/11/98). 2. Allow vehicle to soak long enough (possibly overnight) that the transmission fluid temperature is near the ambient temperature. Perform initial cold startup. 3. Verify ticking noise with the transmission shift selector in "P" (Park) and "N" (Neutral). 4. When ticking noise is confirmed, refer to the Transmission Hardware Application Chart to update transmission hardware as indicated by vehicle/engine application. NOTE FOLLOW ALL OF THE NORMAL SERVICE PROCEDURE AS OUTLINED IN THE APPROPRIATE WORKSHOP MANUAL. NOTE THE BUILD DATE LISTED MAY VARY SLIGHTLY FOR SOME VEHICLE APPLICATIONS. WHEN SERVICE IS REQUIRED ON A Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Accumulator: > 06-21-18 > Oct > 06 > Customer Interest for Accumulator: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up > Page 4970 VEHICLE WITH THIS TICK CONCERN, IT IS RECOMMENDED THAT THE TRANSMISSION BE DISASSEMBLED DOWN TO AND INCLUDING THE COAST CLUTCH PRIOR TO PART ORDERING OR PURCHASE. THIS WILL ALLOW VERIFICATION OF THE CORRECT PARTS REQUIRED. INSPECT THE COAST CLUTCH WHEN REMOVED. IF THE COAST CLUTCH CYLINDER IS THE NEW DESIGN STAMPED, WELDED STEEL USE THE -BA LEVEL OVERDRIVE PLATES (REFER TO THE APPLICATION CHART). IF THE COAST CLUTCH CYLINDER IS THE PREVIOUS E4OD CAST IRON DESIGN USE THE -CA LEVEL OVERDRIVE PLATES AND ANY OTHER ASSOCIATED PARTS RECOMMENDED IN THE TRANSMISSION HARDWARE APPLICATION CHART. CAUTION MIXING COMPONENTS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. CAUTION USING COMPONENTS OTHER THAN AS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Control Module: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Accumulator: All Technical Service Bulletins A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Article No. 99-18-5 09/06/99 ^ TRANSMISSION CONTROL INDICATOR LAMP (TCIL) - TCIL ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) P0782 STORED IN MEMORY - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 AND WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 FORD: 1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1997-1998 MARK VIII 1997-1999 TOWN CAR MERCURY: 1997-1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking 2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782. ACTION Verify if delayed upshift is normal cold shift scheduling or a possible leak past the large diameter 2-3 accumulator seal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using New Generation Star (NGS) Tester, perform all self tests and record DTCs. 2. Monitor rpm, and gear command Parameter Identification Displays (PIDs) with the NGS Tester during the 2-3 shift. 3. If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS Tester, then vehicle has upshifted properly and no repair is necessary. If engine rpm does not drop within 1-2 seconds, continue to Step 4. 4. If engine rpm does not drop when the PCM commands third gear, then replace the 2-3 accumulator piston using the revised Accumulator Piston (F7AZ-7H292-AB). Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Accumulator Piston OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-1-3 WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991805A Replace Accumulator 1.8 Hrs. Piston Per Service Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Control Module: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 4976 Procedure (Includes Diagnosis) 991805B Diagnosis Only (Do Not 0.8 Hr. Use With Operation A) DEALER CODING CONDITION BASIC PART NO CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Control Module: > 99-9-6 > May > 99 > A/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift Accumulator: All Technical Service Bulletins A/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift Article No. 99-9-6 05/17/99 FORD: 1994-1997 THUNDERBIRD 1995-1998 CROWN VICTORIA 1996-1998 MUSTANG LINCOLN-MERCURY: 1993-1998 MARK VIII 1994-1997 COUGAR 1995-1998 GRAND MARQUIS, TOWN CAR LIGHT TRUCK: 1994-1998 ECONOLINE, F-150 1996-1998 EXPLORER 1997-1998 EXPEDITION, F-25O LD, MOUNTAINEER This concern is ONLY for vehicles with Ford Quality Remanufactured (FQR) 4R70W Transmission Exchange Units With Julian build dates between 062-97 And 04099 (corresponding serial numbers are between R0475797 and R0771887). ISSUE A delayed or no 2-3 upshift, primarily when the transmission is cold, may be evident on some vehicles In some cases, Diagnostic Trouble Code (DTC) P0782 may also be present. This may be caused by fluid pressure leakage past the larger diameter seal of the 2-3 accumulator. ACTION Replace the 2-3 accumulator piston using a revised piston. The revised piston will increase seal/bore interference, eliminating any internal leak relating to the 2-3 accumulator piston reducing the possibility of 2-3 upshift concerns. Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Piston OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990906A Replace Accumulator 1.0 Hr. Piston DEALER CODING CONDITION BASIC PART NO. CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Control Module: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up Technical Service Bulletin # 98-20-9 Date: 981012 A/T - E4OD/4R100 Ticking Noise On Start Up Article No. 98-20-9 10/12/98 ^ NOISE - "TICKING" OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES WITH E4OD/4R100 TRANSMISSION AND BUILT THROUGH 6/11/98 ^ TRANSMISSION - E4OD/4R100 - "TICKING" NOISE OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES BUILT THROUGH 6/11/98 LIGHT TRUCK: 1998 ECONOLINE, EXPEDITION, F-150, F-250 LD, NAVIGATOR 1999 F-250 HD, F-350, SUPER DUTY F SERIES ISSUE A "ticking" noise on initial startup with shift selector in "P" or "N" position may occur on some vehicles. This may be caused by the overdrive clutch steel separator plate(s) impacting against the case internal spline. ACTION Replace the specified transmission components per the following Service Procedure. NOTE THE TICKING NOISE TYPICALLY IS ONLY PRESENT DURING INITIAL STARTUP AFTER THE VEHICLE HAS SOAKED LONG ENOUGH FOR THE TRANSMISSION FLUID TEMPERATURE TO REACH NEAR THE AMBIENT TEMPERATURE. THIS NOISE MAY BE HEARD INTERMITTENTLY DURING NORMAL OPERATING TEMPERATURES IN OTHER GEAR RANGES. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982009A Replace Specific 5.0 Hrs. Transmission Hardware F-Series LD 4X2 5.4L 982009B Replace Specific 6.8 Hrs. Transmission Hardware - F-Series LD 4X4 5.4L 982009C Replace Specific 5.0 Hrs. Transmission Hardware - Expedition/Navigator 4X2 5.4L 982009D Replace Specific 6.8 Hrs. Transmission Hardware - Expedition/Navigator 4X4 5.4L 982009E Extra Time To Adjust 0.4 Hr. Four-Wheel Air Suspension Ride Height - Expedition/Navigator Only 982009F Replace Specific 4.6 Hrs. Transmission Hardware - E-Series 5.4L or 6.8L Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Control Module: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up > Page 4985 982009G Replace Specific 4.1 Hrs. Transmission Hardware - E-Series 7.3L 982009H Replace Specific 3.9 Hrs. Transmission Hardware - F-Series HD 4X2 5.4L Or 6.8L 982009I Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 5.4L Or 6.8L 982009J Replace Specific 3.8 Hrs. Transmission Hardware - F-Series HD 4X2 7.3L 982009K Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 7.3L DEALER CODING CONDITION BASIC PART NO. CODE 7B164 07 7G422 07 OASIS CODES: 504000, 597997, 702000 Service Procedure 1. Verify vehicle's build date (Job # 1 built through 6/11/98). 2. Allow vehicle to soak long enough (possibly overnight) that the transmission fluid temperature is near the ambient temperature. Perform initial cold startup. 3. Verify ticking noise with the transmission shift selector in "P" (Park) and "N" (Neutral). 4. When ticking noise is confirmed, refer to the Transmission Hardware Application Chart to update transmission hardware as indicated by vehicle/engine application. NOTE FOLLOW ALL OF THE NORMAL SERVICE PROCEDURE AS OUTLINED IN THE APPROPRIATE WORKSHOP MANUAL. NOTE THE BUILD DATE LISTED MAY VARY SLIGHTLY FOR SOME VEHICLE APPLICATIONS. WHEN SERVICE IS REQUIRED ON A Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Control Module: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up > Page 4986 VEHICLE WITH THIS TICK CONCERN, IT IS RECOMMENDED THAT THE TRANSMISSION BE DISASSEMBLED DOWN TO AND INCLUDING THE COAST CLUTCH PRIOR TO PART ORDERING OR PURCHASE. THIS WILL ALLOW VERIFICATION OF THE CORRECT PARTS REQUIRED. INSPECT THE COAST CLUTCH WHEN REMOVED. IF THE COAST CLUTCH CYLINDER IS THE NEW DESIGN STAMPED, WELDED STEEL USE THE -BA LEVEL OVERDRIVE PLATES (REFER TO THE APPLICATION CHART). IF THE COAST CLUTCH CYLINDER IS THE PREVIOUS E4OD CAST IRON DESIGN USE THE -CA LEVEL OVERDRIVE PLATES AND ANY OTHER ASSOCIATED PARTS RECOMMENDED IN THE TRANSMISSION HARDWARE APPLICATION CHART. CAUTION MIXING COMPONENTS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. CAUTION USING COMPONENTS OTHER THAN AS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Diagrams Band/Clutch Application Chart No. 601 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair Band Apply Servo: Service and Repair INTERMEDIATE SERVO-REPLACEMENT Removal 1. Remove the main control valve body. 2. Remove the intermediate servo. NOTE: Gently tap on the servo cover with a rubber mallet to compress and allow servo assembly to pop up. Installation 1. Install the intermediate band servo. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Page 4993 NOTE: Lubricate the servo seal with clean transmission fluid. 2. Install the main control valve body. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Specifications Case: Specifications Transmission Heat Shield to Case .............................................................................................................................................. 9-12 Nm (77-104 inch lbs.) Main and Lower Control Body to Case ...................................................................................................................................... 9-11 Nm (80-100 inch lbs.) Main Accumulator and Solenoid Body to Case .......................................................................................................................... 9-11 Nm (80-100 inch lbs.) Parking Pawl Abutment to Case ..................................................................................................................................................... 22-27 Nm (16-20 ft. lbs.) Parking Rod Guide Plate to Case ................................................................................................................................................... 22-27 Nm (16-20 ft. lbs.) Manual Control Valve Detent Lever Spring to Case .................................................................................................................. 9-11 Nm (80-100 inch lbs.) Reinforcing Plate to Case ........................................................................................................................................................... 9-11 Nm (80-100 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > Front Case Bushing Case: Service and Repair Front Case Bushing DISASSEMBLY 1. Using the (A) Seal Remover and the (B) Impact Slide Hammer, remove the front case bushing. ASSEMBLY 1. Place the (A) front case bushing onto the (B) Rear Case Bushing Replacer. NOTE: The front case bushing has three lube grooves. The rear case bushing has one lube groove. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > Front Case Bushing > Page 4999 2. Place the (A) front case bushing with the (B) Rear Case Bushing Replacer and the (C) 127 mm (5 inch) Threaded Drawbar through the case and into the rear case bushing. 3. Place the other portion of the (A) Rear Case Bushing Replacer over the (B) 127 mm (5 inch) Threaded Drawbar. Then, install the (C) washer and the (D) nut hand-tight. CAUTION: Make sure the bushing and tool are centered in the bore. 4. Hold the (A) Drawbar with a 1/2 inch wrench while turning the (B) nut with a 1-1/8 inch wrench until the front case bushing is fully seated. Remove the tools. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > Front Case Bushing > Page 5000 Case: Service and Repair Rear Case Bushings Special Tools DISASSEMBLY NOTE: Inspect the case bushing bores for nicks or burrs. Remove any minor nicks or buff s using a fine oil stone. Remove the case bushings only if they show signs of excessive wear or scoring. 1. Using the (A) Seal Remover and the (B) Impact Slide Hammer, remove the rear case bushing. CAUTION: Be careful not to damage the case bore while removing the bushing. NOTE: Always replace both bushings when either bushing is replaced. However, remove and replace only one bushing at a time. Use the other bushing in the case to help align the tool and replacement bushing during installation. ASSEMBLY Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > Front Case Bushing > Page 5001 1. Place the (A) rear case bushing onto the (B) Rear Case Bushing Replacer. NOTE: The rear case bushing has one lube groove. The front case bushing has three lube grooves. 2. Place the other portion of the (A) Rear Case Bushing Replacer and the (B) 127 mm (5 inch) Threaded Drawbar through the case and into the front case bushing. 3. Place the (A) rear case bushing with the (B) Rear Case Bushing Replacer over the (C) 127 mm (5 inch) Threaded Drawbar and into the case. Install the (D) washer and the (E) nut hand-tight. CAUTION: Make sure the bushing and tool are centered in the bore. 4. Hold the (A) drawbar with a 1/2 inch wrench while turning the (B) nut with a 1-1/8 inch wrench until the (C) rear case bushing is fully seated. Remove the tools. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up Technical Service Bulletin # 98-20-9 Date: 981012 A/T - E4OD/4R100 Ticking Noise On Start Up Article No. 98-20-9 10/12/98 ^ NOISE - "TICKING" OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES WITH E4OD/4R100 TRANSMISSION AND BUILT THROUGH 6/11/98 ^ TRANSMISSION - E4OD/4R100 - "TICKING" NOISE OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES BUILT THROUGH 6/11/98 LIGHT TRUCK: 1998 ECONOLINE, EXPEDITION, F-150, F-250 LD, NAVIGATOR 1999 F-250 HD, F-350, SUPER DUTY F SERIES ISSUE A "ticking" noise on initial startup with shift selector in "P" or "N" position may occur on some vehicles. This may be caused by the overdrive clutch steel separator plate(s) impacting against the case internal spline. ACTION Replace the specified transmission components per the following Service Procedure. NOTE THE TICKING NOISE TYPICALLY IS ONLY PRESENT DURING INITIAL STARTUP AFTER THE VEHICLE HAS SOAKED LONG ENOUGH FOR THE TRANSMISSION FLUID TEMPERATURE TO REACH NEAR THE AMBIENT TEMPERATURE. THIS NOISE MAY BE HEARD INTERMITTENTLY DURING NORMAL OPERATING TEMPERATURES IN OTHER GEAR RANGES. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982009A Replace Specific 5.0 Hrs. Transmission Hardware F-Series LD 4X2 5.4L 982009B Replace Specific 6.8 Hrs. Transmission Hardware - F-Series LD 4X4 5.4L 982009C Replace Specific 5.0 Hrs. Transmission Hardware - Expedition/Navigator 4X2 5.4L 982009D Replace Specific 6.8 Hrs. Transmission Hardware - Expedition/Navigator 4X4 5.4L 982009E Extra Time To Adjust 0.4 Hr. Four-Wheel Air Suspension Ride Height - Expedition/Navigator Only 982009F Replace Specific 4.6 Hrs. Transmission Hardware - E-Series 5.4L or 6.8L Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up > Page 5010 982009G Replace Specific 4.1 Hrs. Transmission Hardware - E-Series 7.3L 982009H Replace Specific 3.9 Hrs. Transmission Hardware - F-Series HD 4X2 5.4L Or 6.8L 982009I Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 5.4L Or 6.8L 982009J Replace Specific 3.8 Hrs. Transmission Hardware - F-Series HD 4X2 7.3L 982009K Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 7.3L DEALER CODING CONDITION BASIC PART NO. CODE 7B164 07 7G422 07 OASIS CODES: 504000, 597997, 702000 Service Procedure 1. Verify vehicle's build date (Job # 1 built through 6/11/98). 2. Allow vehicle to soak long enough (possibly overnight) that the transmission fluid temperature is near the ambient temperature. Perform initial cold startup. 3. Verify ticking noise with the transmission shift selector in "P" (Park) and "N" (Neutral). 4. When ticking noise is confirmed, refer to the Transmission Hardware Application Chart to update transmission hardware as indicated by vehicle/engine application. NOTE FOLLOW ALL OF THE NORMAL SERVICE PROCEDURE AS OUTLINED IN THE APPROPRIATE WORKSHOP MANUAL. NOTE THE BUILD DATE LISTED MAY VARY SLIGHTLY FOR SOME VEHICLE APPLICATIONS. WHEN SERVICE IS REQUIRED ON A Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 98-20-9 > Oct > 98 > A/T - E4OD/4R100 Ticking Noise On Start Up > Page 5011 VEHICLE WITH THIS TICK CONCERN, IT IS RECOMMENDED THAT THE TRANSMISSION BE DISASSEMBLED DOWN TO AND INCLUDING THE COAST CLUTCH PRIOR TO PART ORDERING OR PURCHASE. THIS WILL ALLOW VERIFICATION OF THE CORRECT PARTS REQUIRED. INSPECT THE COAST CLUTCH WHEN REMOVED. IF THE COAST CLUTCH CYLINDER IS THE NEW DESIGN STAMPED, WELDED STEEL USE THE -BA LEVEL OVERDRIVE PLATES (REFER TO THE APPLICATION CHART). IF THE COAST CLUTCH CYLINDER IS THE PREVIOUS E4OD CAST IRON DESIGN USE THE -CA LEVEL OVERDRIVE PLATES AND ANY OTHER ASSOCIATED PARTS RECOMMENDED IN THE TRANSMISSION HARDWARE APPLICATION CHART. CAUTION MIXING COMPONENTS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. CAUTION USING COMPONENTS OTHER THAN AS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 98-20-9 > Oct > 98 > A/T E4OD/4R100 Ticking Noise On Start Up Technical Service Bulletin # 98-20-9 Date: 981012 A/T - E4OD/4R100 Ticking Noise On Start Up Article No. 98-20-9 10/12/98 ^ NOISE - "TICKING" OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES WITH E4OD/4R100 TRANSMISSION AND BUILT THROUGH 6/11/98 ^ TRANSMISSION - E4OD/4R100 - "TICKING" NOISE OCCURS ON INITIAL STARTUP WITH SHIFT SELECTOR IN "P" OR "N" POSITION - VEHICLES BUILT THROUGH 6/11/98 LIGHT TRUCK: 1998 ECONOLINE, EXPEDITION, F-150, F-250 LD, NAVIGATOR 1999 F-250 HD, F-350, SUPER DUTY F SERIES ISSUE A "ticking" noise on initial startup with shift selector in "P" or "N" position may occur on some vehicles. This may be caused by the overdrive clutch steel separator plate(s) impacting against the case internal spline. ACTION Replace the specified transmission components per the following Service Procedure. NOTE THE TICKING NOISE TYPICALLY IS ONLY PRESENT DURING INITIAL STARTUP AFTER THE VEHICLE HAS SOAKED LONG ENOUGH FOR THE TRANSMISSION FLUID TEMPERATURE TO REACH NEAR THE AMBIENT TEMPERATURE. THIS NOISE MAY BE HEARD INTERMITTENTLY DURING NORMAL OPERATING TEMPERATURES IN OTHER GEAR RANGES. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982009A Replace Specific 5.0 Hrs. Transmission Hardware F-Series LD 4X2 5.4L 982009B Replace Specific 6.8 Hrs. Transmission Hardware - F-Series LD 4X4 5.4L 982009C Replace Specific 5.0 Hrs. Transmission Hardware - Expedition/Navigator 4X2 5.4L 982009D Replace Specific 6.8 Hrs. Transmission Hardware - Expedition/Navigator 4X4 5.4L 982009E Extra Time To Adjust 0.4 Hr. Four-Wheel Air Suspension Ride Height - Expedition/Navigator Only 982009F Replace Specific 4.6 Hrs. Transmission Hardware - E-Series 5.4L or 6.8L Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 98-20-9 > Oct > 98 > A/T E4OD/4R100 Ticking Noise On Start Up > Page 5017 982009G Replace Specific 4.1 Hrs. Transmission Hardware - E-Series 7.3L 982009H Replace Specific 3.9 Hrs. Transmission Hardware - F-Series HD 4X2 5.4L Or 6.8L 982009I Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 5.4L Or 6.8L 982009J Replace Specific 3.8 Hrs. Transmission Hardware - F-Series HD 4X2 7.3L 982009K Replace Specific 4.6 Hrs. Transmission Hardware - F-Series HD 4X4 7.3L DEALER CODING CONDITION BASIC PART NO. CODE 7B164 07 7G422 07 OASIS CODES: 504000, 597997, 702000 Service Procedure 1. Verify vehicle's build date (Job # 1 built through 6/11/98). 2. Allow vehicle to soak long enough (possibly overnight) that the transmission fluid temperature is near the ambient temperature. Perform initial cold startup. 3. Verify ticking noise with the transmission shift selector in "P" (Park) and "N" (Neutral). 4. When ticking noise is confirmed, refer to the Transmission Hardware Application Chart to update transmission hardware as indicated by vehicle/engine application. NOTE FOLLOW ALL OF THE NORMAL SERVICE PROCEDURE AS OUTLINED IN THE APPROPRIATE WORKSHOP MANUAL. NOTE THE BUILD DATE LISTED MAY VARY SLIGHTLY FOR SOME VEHICLE APPLICATIONS. WHEN SERVICE IS REQUIRED ON A Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 98-20-9 > Oct > 98 > A/T E4OD/4R100 Ticking Noise On Start Up > Page 5018 VEHICLE WITH THIS TICK CONCERN, IT IS RECOMMENDED THAT THE TRANSMISSION BE DISASSEMBLED DOWN TO AND INCLUDING THE COAST CLUTCH PRIOR TO PART ORDERING OR PURCHASE. THIS WILL ALLOW VERIFICATION OF THE CORRECT PARTS REQUIRED. INSPECT THE COAST CLUTCH WHEN REMOVED. IF THE COAST CLUTCH CYLINDER IS THE NEW DESIGN STAMPED, WELDED STEEL USE THE -BA LEVEL OVERDRIVE PLATES (REFER TO THE APPLICATION CHART). IF THE COAST CLUTCH CYLINDER IS THE PREVIOUS E4OD CAST IRON DESIGN USE THE -CA LEVEL OVERDRIVE PLATES AND ANY OTHER ASSOCIATED PARTS RECOMMENDED IN THE TRANSMISSION HARDWARE APPLICATION CHART. CAUTION MIXING COMPONENTS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. CAUTION USING COMPONENTS OTHER THAN AS LISTED IN THIS CHART MAY CAUSE TRANSMISSION SHIFT CONCERNS AND/OR DAMAGE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Page 5019 Clutch: Specifications Low/Reverse OWC Inner Race to Case ......................................................................................................................................... 24-34 Nm (18-25 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Diagnostic Aids Band/Clutch Application Chart No. 601 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Diagnostic Aids > Page 5022 Clutch: Exploded Views Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Diagnostic Aids > Page 5023 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Diagnostic Aids > Page 5024 Part 1 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Diagnostic Aids > Page 5025 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch Clutch: Service and Repair Center Support Clutch Special Tools DISASSEMBLY 1. Using the (A) O-Ring Tool, remove and discard the (B) direct clutch seal rings. Remove the (C) No. 6 center support thrust washer. 2. Inspect the following for contamination or damage. Clean or replace, as necessary. - No. 6 center support thrust washer (A). - Seal ring grooves (B). - Inner hub diameter (C). - Outer hub diameter (D). - Feed bolt threads (E). - Ball bearing (F). ASSEMBLY 1. Follow the removal procedure in reverse order. - Lightly lubricate the thrust washer with petroleum jelly to hold it in place during assembly. - Install new seals. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5028 Clutch: Service and Repair Coast Clutch Part 1 Of 2 Part 2 Of 2 Special Tools DISASSEMBLY Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5029 1. Remove the overdrive sun gear. 2. Remove the coast clutch pressure plate retainer ring. 3. Remove the (A) coast clutch pressure plate and the (B) clutch plates. NOTE: Tag the parts for identification during installation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5030 4. Using the (A) Clutch Spring Compressor, compress the (B) coast clutch piston return spring and remove the (C) coast clutch piston return spring retaining ring. Remove the tool. Discard the retaining ring. CAUTION: Do not fully compress the return springs or damage to return spring may occur. 5. Remove the coast clutch piston return spring. 6. Remove the coast clutch piston apply ring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5031 7. Remove the coast clutch piston. 8. Remove the coast clutch piston outer seal. 9. Remove the coast clutch piston inner seal. ASSEMBLY NOTE: Soak all friction clutch plates for 15 minutes in clean MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. NOTE: Prior to installation, lightly lubricate all O-ring seals with clean MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. 1. Install the coast clutch piston inner seal. NOTE: Make sure the seal lip faces the coast clutch cylinder. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5032 2. Install the coast clutch piston outer seal. NOTE: Make sure the seal lip faces the coast clutch piston. 3. Install the coast clutch piston. 4. Install the coast clutch piston apply ring. 5. Install the coast clutch piston return spring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5033 6. Using the (A) Clutch Spring Compressor, compress the (B) coast clutch piston return spring and install the new (C) coast clutch piston return spring retaining ring. Remove the tool. CAUTION: Do not fully compress the return springs or damage to return spring may occur. 7. Alternately install the (A) steel and the (B) friction clutch plates, beginning with a steel plate and ending with the (C) coast clutch pressure plate. 8. Install the selective coast clutch pressure plate retainer ring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5034 9. Check the stack-up clearance. 1. Using a feeler gauge, check the stack-up clearance in three places, 120 degrees apart. 2. If the clearance is not to specification, install the correct coast clutch pressure plate retainer snap ring and recheck the clearance. 10. Install the overdrive sun gear, with the short end of the gear downward. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5035 Clutch: Service and Repair Direct Clutch Special Tools DISASSEMBLY Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5036 1. Remove the intermediate one-way clutch outer race, and inspect for damage. 2. Remove the (A) top end cap and the (B) intermediate one-way clutch. Inspect the sprags, cage, and top end cap for excessive wear or damage. 3. Remove the bottom end cap and inspect for damage. 4. Remove the No. 7 intermediate one-way clutch thrust washer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5037 5. Remove the No. 8A intermediate brake drum thrust washer. 6. Remove the direct clutch pressure plate retaining ring. 7. Remove the (A) direct clutch pressure plate and the (B) clutch pack. NOTE: Tag the parts for identification during installation. 8. Using the (A) Clutch Spring Compressor, compress the (B) direct clutch return spring assembly and remove the (C) direct clutch return spring retaining ring. Remove the tool. CAUTION: Do not fully compress the return springs or the spring may break. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5038 9. Remove the direct clutch return spring assembly. 10. Remove the direct clutch piston. 11. Using the (A) O-Ring Tool, remove the direct clutch piston (B) inner and (C) outer seals. 12. Inspect the clutch cylinder thrust surfaces, piston bore, and clutch plate splines for scores, buffs or wear. Replace the clutch cylinder if it is badly scored or damaged. 13. Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace, if necessary. Inspect the check balls for freedom of movement. 14. Check the clutch release spring for distortion and cracks. Replace the spring if it is distorted or cracked. 15. Inspect the friction clutch plates, steel clutch plates, and clutch pressure plate for worn or scored surfaces. Replace all parts that are scored, burred or burnt. 16. Check the clutch plates for flatness and wear on the clutch hub splines. Discard any plate that does not slide freely on the splines or that is not flat. 17. Check the clutch hub thrust surfaces for scores and the clutch hub splines for wear. Replace all worn parts. ASSEMBLY NOTE: Soak the clutch plates for 15 minutes in clean MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5039 1. Install the direct clutch piston inner seal. NOTE: The seal lip must face downward. 2. Install the direct clutch piston outer seal. NOTE: The seal lip must face downward. 3. Inspect the direct clutch piston check ball. 1. Check for freedom of movement and proper seating. 2. Clean the direct clutch piston with solvent, if necessary. 3. Replace the direct clutch piston, if damaged. 4. Install the direct clutch piston. NOTE: The piston should rotate freely in the drum. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5040 5. Install the direct clutch return spring assembly. NOTE: Make sure the (A) protrusions are properly engaged with the (B) lugs. 6. Using the (A) Clutch Spring Compressor, compress the (B) direct clutch return spring assembly and install the (C) direct clutch return spring retaining ring. Remove the tool. CAUTION: Do not fully compress the return springs or damage to spring may occur. 7. Alternately install the (A) steel and the (B) friction clutch plates, beginning with a steel plate and ending with the (C) direct clutch pressure plate. CAUTION: Mixing or using friction plates without the grooves will cause shift concerns and can cause damage. NOTE: The direct clutch friction plates have lube grooves in the friction material. NOTE: The number of plates are model dependent. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5041 8. Install the selective direct clutch pressure plate retaining ring. 9. Check the stack-up clearance. 1. Using a feeler gauge, check the stack-up clearance in three places, 120 degrees apart. 2. If the clearance is not to specification, install the correct selective direct clutch pressure plate retaining ring and recheck the clearance. 10. Install the No. 7 intermediate one-way clutch large thrust washer, aligning the (A) tabs with the (B) notches. 11. Install the bottom end cap. NOTE: The top and bottom end caps are identical. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5042 12. Install the (A) intermediate one-way clutch over the inner race. Install the (B) top end cap. NOTE: The (A) lip on the intermediate one-way clutch must face upward. 13. Install the intermediate one-way clutch outer race. NOTE: The shoulder on the outer race must face upward. NOTE: When installed, the outer race must rotate counterclockwise. 14. Install the No. 8A intermediate brake drum thrust washer, engaging the (A) tabs with the (B) slots. NOTE: Lightly lubricate the thrust washer with petroleum jelly to hold it in place during assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5043 Clutch: Service and Repair Forward Clutch Part 1 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5044 Part 2 Of 2 Special Tools DISASSEMBLY 1. Remove the No. 9A forward clutch thrust bearing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5045 2. Remove the No. 8B forward clutch needle bearing assembly. 3. Remove the 2 interlocking cast iron forward clutch cylinder seals. 4. Remove the selective forward clutch pressure plate retaining ring. 5. Remove the (A) top forward clutch pressure plate, the (B) clutch pack (number of plates are model dependent), the (C) forward clutch pressure spring and the (D) bottom forward clutch pressure plate. NOTE: Tag the parts for identification during installation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5046 6. Remove the forward clutch piston return spring retaining ring. 7. Remove the forward clutch piston return spring. 8. Remove the forward clutch piston apply ring. 9. Using compressed air, remove the forward clutch piston. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5047 10. Remove the outer forward clutch piston seal. 11. Using the O-Ring Tool, remove the forward clutch piston inner seal. 12. Inspect the clutch cylinder thrust surfaces, piston bore, and clutch plate splines for scores, burrs or wear. Replace the clutch cylinder if it is badly scored or damaged. 13. Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace, if necessary. Inspect the check balls for freedom of movement. 14. Check the clutch release spring for distortion and cracks. Replace the spring if it is distorted or cracked. 15. Inspect the friction clutch plates, steel clutch plates, and clutch pressure plate for worn or scored surfaces. Replace all parts that are scored, burred or burnt. 16. Check the clutch plates for flatness and wear on the clutch hub splines. Discard any plate that does not slide freely on the splines or that is not flat. 17. Check the clutch hub thrust surfaces for scores and the clutch hub splines for wear. Replace all worn parts. ASSEMBLY NOTE: Soak the clutch plates for 15 minutes in clean MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. 1. Install the forward clutch piston inner seal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5048 2. Inspect the forward clutch piston check ball. 1. Check for freedom of movement and proper seating. 2. Clean with a suitable solvent, if necessary. 3. Replace the forward clutch piston assembly, if necessary. 3. Install the forward clutch piston outer seal. NOTE: Make sure the seal lip is facing upward. 4. Install the (A) forward clutch piston with the (B) Lip Seal Protector. 5. Install the (A) steel forward clutch piston apply ring into the (B) forward clutch piston groove. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5049 6. Install the forward clutch piston return spring, with the (A) spring fingers against the (B) forward clutch piston apply ring. Make sure the (C) notch is positioned so that both ends of the (D) forward clutch piston apply ring are visible. CAUTION: To ensure durability, the notch between the spring fingers must be positioned so that both ends of the forward clutch piston apply ring are visible. 7. Install the forward clutch piston return spring retaining ring. Make sure it is properly seated in the groove. 8. Install the (A) bottom forward clutch pressure plate with beveled face downward, the (B) forward clutch pressure spring, the (C) clutch pack (number of plates are model-dependent), and the (D) top forward clutch pressure plate. 9. Install the selective forward clutch pressure plate retaining ring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5050 10. Check the stack-up clearance. 1. Using a feeler gauge, check the stack-up clearance in three places, 120 degrees apart. 2. If the clearance is not to specification, install the correct selective forward clutch pressure plate retaining ring and recheck the clearance. 11. Install the No. 8B forward clutch needle bearing. NOTE: Lightly lubricate the needle bearing with petroleum jelly to hold it in place during assembly. NOTE: The bearing large inner diameter radius must face inward. 12. Install the two new cast iron forward clutch cylinder seals in the grooves. NOTE: Stagger the interlocking opening on the seals 180 degrees apart. 13. Install the No. 9A forward clutch thrust bearing. NOTE: Lightly lubricate the thrust bearing with petroleum jelly to hold it in place during assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5051 NOTE: The black side of the bearing must face upward. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5052 Clutch: Service and Repair Center Support Clutch Special Tools DISASSEMBLY 1. Using the (A) O-Ring Tool, remove and discard the (B) direct clutch seal rings. Remove the (C) No. 6 center support thrust washer. 2. Inspect the following for contamination or damage. Clean or replace, as necessary. - No. 6 center support thrust washer (A). - Seal ring grooves (B). - Inner hub diameter (C). - Outer hub diameter (D). - Feed bolt threads (E). - Ball bearing (F). ASSEMBLY 1. Follow the removal procedure in reverse order. - Lightly lubricate the thrust washer with petroleum jelly to hold it in place during assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5053 - Install new seals. Coast Clutch Part 1 Of 2 Part 2 Of 2 Special Tools DISASSEMBLY Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5054 1. Remove the overdrive sun gear. 2. Remove the coast clutch pressure plate retainer ring. 3. Remove the (A) coast clutch pressure plate and the (B) clutch plates. NOTE: Tag the parts for identification during installation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5055 4. Using the (A) Clutch Spring Compressor, compress the (B) coast clutch piston return spring and remove the (C) coast clutch piston return spring retaining ring. Remove the tool. Discard the retaining ring. CAUTION: Do not fully compress the return springs or damage to return spring may occur. 5. Remove the coast clutch piston return spring. 6. Remove the coast clutch piston apply ring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5056 7. Remove the coast clutch piston. 8. Remove the coast clutch piston outer seal. 9. Remove the coast clutch piston inner seal. ASSEMBLY NOTE: Soak all friction clutch plates for 15 minutes in clean MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. NOTE: Prior to installation, lightly lubricate all O-ring seals with clean MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. 1. Install the coast clutch piston inner seal. NOTE: Make sure the seal lip faces the coast clutch cylinder. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5057 2. Install the coast clutch piston outer seal. NOTE: Make sure the seal lip faces the coast clutch piston. 3. Install the coast clutch piston. 4. Install the coast clutch piston apply ring. 5. Install the coast clutch piston return spring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5058 6. Using the (A) Clutch Spring Compressor, compress the (B) coast clutch piston return spring and install the new (C) coast clutch piston return spring retaining ring. Remove the tool. CAUTION: Do not fully compress the return springs or damage to return spring may occur. 7. Alternately install the (A) steel and the (B) friction clutch plates, beginning with a steel plate and ending with the (C) coast clutch pressure plate. 8. Install the selective coast clutch pressure plate retainer ring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5059 9. Check the stack-up clearance. 1. Using a feeler gauge, check the stack-up clearance in three places, 120 degrees apart. 2. If the clearance is not to specification, install the correct coast clutch pressure plate retainer snap ring and recheck the clearance. 10. Install the overdrive sun gear, with the short end of the gear downward. Direct Clutch Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5060 DISASSEMBLY 1. Remove the intermediate one-way clutch outer race, and inspect for damage. 2. Remove the (A) top end cap and the (B) intermediate one-way clutch. Inspect the sprags, cage, and top end cap for excessive wear or damage. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5061 3. Remove the bottom end cap and inspect for damage. 4. Remove the No. 7 intermediate one-way clutch thrust washer. 5. Remove the No. 8A intermediate brake drum thrust washer. 6. Remove the direct clutch pressure plate retaining ring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5062 7. Remove the (A) direct clutch pressure plate and the (B) clutch pack. NOTE: Tag the parts for identification during installation. 8. Using the (A) Clutch Spring Compressor, compress the (B) direct clutch return spring assembly and remove the (C) direct clutch return spring retaining ring. Remove the tool. CAUTION: Do not fully compress the return springs or the spring may break. 9. Remove the direct clutch return spring assembly. 10. Remove the direct clutch piston. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5063 11. Using the (A) O-Ring Tool, remove the direct clutch piston (B) inner and (C) outer seals. 12. Inspect the clutch cylinder thrust surfaces, piston bore, and clutch plate splines for scores, buffs or wear. Replace the clutch cylinder if it is badly scored or damaged. 13. Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace, if necessary. Inspect the check balls for freedom of movement. 14. Check the clutch release spring for distortion and cracks. Replace the spring if it is distorted or cracked. 15. Inspect the friction clutch plates, steel clutch plates, and clutch pressure plate for worn or scored surfaces. Replace all parts that are scored, burred or burnt. 16. Check the clutch plates for flatness and wear on the clutch hub splines. Discard any plate that does not slide freely on the splines or that is not flat. 17. Check the clutch hub thrust surfaces for scores and the clutch hub splines for wear. Replace all worn parts. ASSEMBLY NOTE: Soak the clutch plates for 15 minutes in clean MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. 1. Install the direct clutch piston inner seal. NOTE: The seal lip must face downward. 2. Install the direct clutch piston outer seal. NOTE: The seal lip must face downward. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5064 3. Inspect the direct clutch piston check ball. 1. Check for freedom of movement and proper seating. 2. Clean the direct clutch piston with solvent, if necessary. 3. Replace the direct clutch piston, if damaged. 4. Install the direct clutch piston. NOTE: The piston should rotate freely in the drum. 5. Install the direct clutch return spring assembly. NOTE: Make sure the (A) protrusions are properly engaged with the (B) lugs. 6. Using the (A) Clutch Spring Compressor, compress the (B) direct clutch return spring assembly and install the (C) direct clutch return spring retaining ring. Remove the tool. CAUTION: Do not fully compress the return springs or damage to spring may occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5065 7. Alternately install the (A) steel and the (B) friction clutch plates, beginning with a steel plate and ending with the (C) direct clutch pressure plate. CAUTION: Mixing or using friction plates without the grooves will cause shift concerns and can cause damage. NOTE: The direct clutch friction plates have lube grooves in the friction material. NOTE: The number of plates are model dependent. 8. Install the selective direct clutch pressure plate retaining ring. 9. Check the stack-up clearance. 1. Using a feeler gauge, check the stack-up clearance in three places, 120 degrees apart. 2. If the clearance is not to specification, install the correct selective direct clutch pressure plate retaining ring and recheck the clearance. 10. Install the No. 7 intermediate one-way clutch large thrust washer, aligning the (A) tabs with the (B) notches. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5066 11. Install the bottom end cap. NOTE: The top and bottom end caps are identical. 12. Install the (A) intermediate one-way clutch over the inner race. Install the (B) top end cap. NOTE: The (A) lip on the intermediate one-way clutch must face upward. 13. Install the intermediate one-way clutch outer race. NOTE: The shoulder on the outer race must face upward. NOTE: When installed, the outer race must rotate counterclockwise. 14. Install the No. 8A intermediate brake drum thrust washer, engaging the (A) tabs with the (B) slots. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5067 NOTE: Lightly lubricate the thrust washer with petroleum jelly to hold it in place during assembly. Forward Clutch Part 1 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5068 Part 2 Of 2 Special Tools DISASSEMBLY 1. Remove the No. 9A forward clutch thrust bearing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5069 2. Remove the No. 8B forward clutch needle bearing assembly. 3. Remove the 2 interlocking cast iron forward clutch cylinder seals. 4. Remove the selective forward clutch pressure plate retaining ring. 5. Remove the (A) top forward clutch pressure plate, the (B) clutch pack (number of plates are model dependent), the (C) forward clutch pressure spring and the (D) bottom forward clutch pressure plate. NOTE: Tag the parts for identification during installation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5070 6. Remove the forward clutch piston return spring retaining ring. 7. Remove the forward clutch piston return spring. 8. Remove the forward clutch piston apply ring. 9. Using compressed air, remove the forward clutch piston. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5071 10. Remove the outer forward clutch piston seal. 11. Using the O-Ring Tool, remove the forward clutch piston inner seal. 12. Inspect the clutch cylinder thrust surfaces, piston bore, and clutch plate splines for scores, burrs or wear. Replace the clutch cylinder if it is badly scored or damaged. 13. Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace, if necessary. Inspect the check balls for freedom of movement. 14. Check the clutch release spring for distortion and cracks. Replace the spring if it is distorted or cracked. 15. Inspect the friction clutch plates, steel clutch plates, and clutch pressure plate for worn or scored surfaces. Replace all parts that are scored, burred or burnt. 16. Check the clutch plates for flatness and wear on the clutch hub splines. Discard any plate that does not slide freely on the splines or that is not flat. 17. Check the clutch hub thrust surfaces for scores and the clutch hub splines for wear. Replace all worn parts. ASSEMBLY NOTE: Soak the clutch plates for 15 minutes in clean MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. 1. Install the forward clutch piston inner seal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5072 2. Inspect the forward clutch piston check ball. 1. Check for freedom of movement and proper seating. 2. Clean with a suitable solvent, if necessary. 3. Replace the forward clutch piston assembly, if necessary. 3. Install the forward clutch piston outer seal. NOTE: Make sure the seal lip is facing upward. 4. Install the (A) forward clutch piston with the (B) Lip Seal Protector. 5. Install the (A) steel forward clutch piston apply ring into the (B) forward clutch piston groove. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5073 6. Install the forward clutch piston return spring, with the (A) spring fingers against the (B) forward clutch piston apply ring. Make sure the (C) notch is positioned so that both ends of the (D) forward clutch piston apply ring are visible. CAUTION: To ensure durability, the notch between the spring fingers must be positioned so that both ends of the forward clutch piston apply ring are visible. 7. Install the forward clutch piston return spring retaining ring. Make sure it is properly seated in the groove. 8. Install the (A) bottom forward clutch pressure plate with beveled face downward, the (B) forward clutch pressure spring, the (C) clutch pack (number of plates are model-dependent), and the (D) top forward clutch pressure plate. 9. Install the selective forward clutch pressure plate retaining ring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5074 10. Check the stack-up clearance. 1. Using a feeler gauge, check the stack-up clearance in three places, 120 degrees apart. 2. If the clearance is not to specification, install the correct selective forward clutch pressure plate retaining ring and recheck the clearance. 11. Install the No. 8B forward clutch needle bearing. NOTE: Lightly lubricate the needle bearing with petroleum jelly to hold it in place during assembly. NOTE: The bearing large inner diameter radius must face inward. 12. Install the two new cast iron forward clutch cylinder seals in the grooves. NOTE: Stagger the interlocking opening on the seals 180 degrees apart. 13. Install the No. 9A forward clutch thrust bearing. NOTE: Lightly lubricate the thrust bearing with petroleum jelly to hold it in place during assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5075 NOTE: The black side of the bearing must face upward. One-Way Clutch, A/T DISASSEMBLY 1. Remove the (A) output shaft ring gear and the (B) No. 12 thrust bearing. 2. If necessary, remove the low one-way clutch assembly by rotating it counterclockwise to unlock the tabs. 3. Inspect the following: - Reverse clutch hub thrust surfaces for scores. - Reverse clutch hub splines for wear. - Outer and inner low/reverse one-way clutch race for scores and damaged surface areas where rollers contact races. - Rollers and springs for excessive wear or damage. - Spring and cage. ASSEMBLY 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Center Support Clutch > Page 5076 Reverse Clutch DISASSEMBLY 1. Remove the reverse clutch piston outer lip seal. 2. Remove the reverse clutch piston inner lip seal. ASSEMBLY 1. Follow the removal procedure in reverse order. - Make sure the lip on the seal faces the back side of the piston. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Tools and Equipment > Coast Clutch Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Tools and Equipment > Coast Clutch > Page 5079 Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Tools and Equipment > Coast Clutch > Page 5080 Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair Automatic Transmission Dipstick - Dipstick Tube: Service and Repair REMOVAL 1. If equipped, turn the air suspension switch off. 2. Disconnect the battery ground cable. 3. Remove the fluid level indicator. 4. Raise the vehicle on a hoist. 5. Remove the RT front wheel. 6. Remove the inner wheel liner. 7. Remove the bolt. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair > Page 5084 8. Remove the oil filler tube. NOTE: It may be necessary to disconnect the wiring harness from the starter motor to remove the oil filler tube. INSTALLATION 1. Install the oil filler tube. NOTE: Coat the O-ring at the bottom of the oil filler tube with transmission fluid. If removed install the starter wiring harness. 2. Install the bolt. 3. Install the inner wheel liner. 4. Install the RT front wheel. 5. Lower the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair > Page 5085 6. Install the fluid level indicator. 7. Connect the battery ground cable. 8. If equipped, turn the air suspension switch off. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Extension Housing to Case ............................................................................................................................................................ 41-54 Nm (30-40 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 5089 Extension Housing: Service and Repair Special Tools REMOVAL 1. Disconnect the battery ground cable. WARNING: ON VEHICLES EQUIPPED WITH AN AUXILIARY BATTERY, BOTH THE NEGATIVE AND POSITIVE BATTERY CABLES MUST BE DISCONNECTED. WARNING: ON VEHICLES EQUIPPED WITH A 7.3L ENGINE, BOTH THE PRIMARY AND SECONDARY BATTERIES MUST BE DISCONNECTED. 2. Raise and support the vehicle. 3. Remove the driveshaft. 4. Remove the transmission-mounted parking brake assembly (if so equipped). 5. Remove the transmission insulator and retainer-to-crossmember retaining nuts. 6. Secure the (A) High lift Transmission Jack with the (B) E40D Transmission Jack Adapter to the (C) transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 5090 7. Raise the transmission jack until the (A) transmission insulator and retainer studs are separated from the (B) transmission support crossmember. 8. Remove the (A) bolts and the (B) transmission insulator and retainer. 9. Disconnect the (A) harness connector and position it aside. Remove the (B) bolt and the (C) vehicle speed sensor (VSS). 10. With a suitable drain pan properly positioned, remove the 8 (A) bolts, the (B) stud and the (C) extension housing. NOTE: Super Duty applications use a special 4x4 extension housing. NOTE: As the fasteners are removed, note the size of each for proper location during installation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 5091 11. Remove and discard the extension housing gasket. INSTALLATION 1. Place the new extension housing gasket on the extension housing. NOTE: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly. 2. Install the (A) extension housing, the 8 (B) bolts and the (C) stud. NOTE: Make sure the fasteners are installed in their proper locations as noted during removal. 3. Install the (A) Vehicle Speed Sensor (VSS) and the (B) bolt. Connect the (C) harness connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 5092 4. Install the (A) transmission insulator and retainer and the (B) bolts. 5. Lower the transmission jack while aligning the (A) transmission insulator and retainer studs with the holes in the (B) transmission support crossmember. Allow the full weight of the transmission to rest on the transmission support crossmember. 6. Install the transmission insulator and retainer-to-crossmember retaining nuts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 5093 7. Remove the (A) High lift Transmission Jack with the (B) E40D Transmission Jack Adapter from the (C) transmission. 8. Reinstall the bolts removed to install the jack adapter. 9. Install the transmission-mounted parking brake assembly (if so equipped). 10. Install the driveshaft. 11. Remove the supports and lower the vehicle. 12. Connect the battery ground cable. 13. Fill the transmission to the specified level with MERCON (R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 5098 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 5099 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications With E4OD Transmission A/T Fluid 4x2 ....................................................................................................................................... ........................................................... 15L (15.9 Qt) A/T Fluid 4x4 ....................................................................................................................................... ........................................................ 15.5L (16.4 Qt) NOTE: With engine at operating temperature, shift through all gears. Check fluid in PARK add fluid as needed. With 4R70W Transmission A/T Fluid .............................................................................................................................................. ......................................................... 13.1L (13.9 Qt) NOTE: With engine at operating temperature, shift through all gears. Check fluid in PARK add fluid as needed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 5102 Fluid - A/T: Fluid Type Specifications E4OD Fluid Type ............................................................................................................................................ ............................................... MERCON(R) V ATF 4R70W Fluid Type ............................................................................................................................................ ............................................... MERCON(R) V ATF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5103 Fluid - A/T: Diagrams PARK Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5104 PARK Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5105 PARK Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5106 PARK Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5107 2 ND GEAR Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5108 2 ND GEAR Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5109 TCC RELEASE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5110 TCC RELEASE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5111 LINE/SRV PRESSURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5112 PARK NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5113 PARK NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5114 1ST GEAR NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5115 2ND GEAR NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5116 3RD GEAR NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5117 4TH GEAR NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5118 MANUAL 3RD GEAR NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5119 MANUAL 2ND GEAR NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5120 MANUAL 1ST GEAR NON-PTO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5121 Fluid - A/T: Service and Repair REMOVAL 1. Disconnect the battery. WARNING: ON VEHICLES EQUIPPED WITH AN AUXILIARY BATTERY, BOTH THE NEGATIVE AND POSITIVE BATTERY CABLES MUST BE DISCONNECTED. WARNING: ON VEHICLES EQUIPPED WITH A 7.3L ENGINE, BOTH THE PRIMARY AND SECONDARY BATTERIES MUST BE DISCONNECTED. 2. Raise and support the vehicle. 3. Disconnect the connector. 4. Remove the transmission fluid pan and the gasket. 1. Loosen, but do not remove, the bolts. 2. Remove the front and side bolts. 3. Lower the front of the fluid pan and allow the fluid to drain. 4. Remove the remaining bolts and the fluid pan. NOTE: Do not discard the gasket unless damaged. This is a reusable gasket. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5122 5. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary. CAUTION: When replacing the transmission fluid and filter and seal assembly, the torque converter, transmission cooler, cooler lines and Cooler Bypass Valve (CBV) must be thoroughly flushed to remove any contamination. NOTE: After removal, discard the filter and seal assembly. 6. If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore. CAUTION: Be careful not to scratch or damage the aluminum bore. The new seal may leak. 7. On all except vehicles equipped with a 7.3L engine, remove the torque converter drain plug cover. 8. On vehicles equipped with the 7.3L engine, remove the 5 (A) bolts and the (B) flywheel inspection cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5123 9. With a drain pan properly positioned, remove and discard the torque converter drain plug. Allow the fluid to drain. NOTE: The 7.3L engine-style transmission case is shown, others are similar. 10. Flush the fluid cooler and fluid cooler lines. INSTALLATION 1. After the torque converter has drained, install a new drain plug. NOTE: The 7.3L engine-style transmission case is shown, others are similar. 2. On all except vehicles equipped with a 7.3L engine, install the torque converter drain plug cover. 3. On vehicles equipped with the 7.3L engine, install the (A) flywheel inspection cover and the 5 (B) bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5124 4. Select the appropriate (A) 4x2-style or (B) 4x4-style filter assembly and transmission pan. CAUTION: Mixing (A) 4x2-style and (B) 4x4-style transmission fluid filters and transmission pan assembly components can cause transmission damage. 5. Press the fluid filter and seal assembly into the pump bore until seated. NOTE: Prior to installation, lightly lubricate the seal with clean MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. 6. Position the (A) gasket onto the cleaned fluid pan. Make sure the (B) magnet is positioned over the dimple in the fluid pan. NOTE: Do not discard the gasket unless damaged. This is a reusable gasket. NOTE: Apply a light coat of petroleum jelly to hold the gasket to the fluid pan. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5125 7. Install the (A) pan with gasket. Alternately tighten the (B) bolts. 8. Connect the connector. 9. Remove the supports and lower the vehicle. 10. Connect the battery ground cable. 11. Refill the transmission. 1. Add 6.2 liters (6.5 quarts) of MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent transmission fluid to the transmission through the fluid filler tube. 2. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements. 3. Check and adjust the transmission fluid, in 0.24 liter (0.5 pint) increments, to the proper level (cross-hatched area of the fluid level indicator at normal operating temperature. CAUTION: Use only MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. The use of any other fluids can result in the transmission failing to operate in a normal manner or failure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications Connector-Cooler Line to Case ...................................................................................................................................................... 27-33 Nm (20-24 ft. lbs.) Connector-Radiator Nipple ............................................................................................................................................................ 23-31 Nm (17-23 ft. lbs.) Connectors, Radiator-to Tube ........................................................................................................................................................ 24-31 Nm (20-23 ft. lbs.) Cooler Tube-to-CBV .................................................................................... ................................................................................. 16-24 Nm (12-18 ft. lbs.) Auxiliary Cooler Tube .............................................................................................................................................................. ..... 22-30 Nm (16-22 ft. lbs.) Center Support Fluid Feed Bolt ....................................................................................................................................................... 11-16 Nm (8-12 ft. lbs.) Line Pressure to Case-Plug ........................................................................... ..................................................................................... 8-16 Nm (6-12 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 5129 Fluid Line/Hose: Service and Repair REMOVAL 1. Remove the fluid cooler tubes. 1. Remove the fluid cooler tubes from the cooler bypass valves. 2. Remove the fluid cooler tube from the transmission fluid cooler and the radiator. 3. Remove the fluid cooler tube from the transmission fluid cooler and the radiator. INSTALLATION 1. Install the fluid cooler tubes. - Install the fluid cooler tubes from the radiator and the transmission fluid cooler. - Install the fluid cooler tube from the transmission fluid cooler to the cooler bypass valve. - Install the fluid cooler tube from the radiator to the cooler bypass valve. 2. Fill the transmission with the specified fluid to the proper level and inspect for leaks. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Transmission Pan to Case .............................................................................................................................................................. 14-16 Nm (10-12 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Control Assembly to Pump ............................................................................................................................................................ 24-31 Nm (18-23 ft. lbs.) Pump Body to Case ..................................................................................... ................................................................................... 24-31 Nm (18-23 ft. lbs.) Stator Support to Pump Body ..................................................................................................................................................... 9-11 Nm (80-100 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 5136 Fluid Pump: Service and Repair Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 5137 Part 1 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 5138 Part 2 Of 2 DISASSEMBLY 1. Using the (A) Seal Remover and the (B) Impact Slide Hammer, remove the (C) front pump seal. NOTE: Inspect and replace the front pump seal, if damaged. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 5139 2. Remove the front pump stator support seal. 3. Remove the 2 Teflon coast clutch seals. 4. Remove the pump outer diameter square-cut front pump seal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 5140 5. Remove and discard the (A) orifice cup plug and the (B) spring and stop assembly. Make sure the old (C) rubber stop is removed. Clean and inspect the bore, making sure it is clean of any debris. CAUTION: Do not reuse the orifice cup plug or spring and stop assembly. Failure to replace these parts may cause repeat repairs. Make sure the old rubber stop is removed (it may become separated from the spring assembly). CAUTION: Use care not to damage any machined surfaces of the stator support. 6. Separate the pump control body from the pump body. 1. Remove the 11 bolts. 2. Support the pump body. 3. Remove the (A) bolt and separate the (B) pump body from the (C) pump control body. NOTE: Obtain Pump Banding Tool and one 10 mm bolt prior to removing the pump body bolts. This tool is needed to align the pump with the control body assembly during reassembly. 7. Remove the converter clutch shift valve assembly, converter regulator valve assembly, and main regulator boost valve and sleeve assembly. 1. Remove the retainer clip with a small screwdriver or tweezers then remove the converter clutch shift valve assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 5141 2. Remove the retainer clip with a small screwdriver or tweezers then remove the converter regulator valve assembly. 3. Remove the retainer clip with a small screwdriver or tweezers then remove the main regulator valve assembly. CAUTION: Do not remove any of the remaining cup plugs unless directed to do so in other steps. Do not remove the stator support from the control body. This can distort the surface of the control body. NOTE: Inspect the main regulator booster valve and sleeve assembly. If the pump valve bore is not damaged but the valve and sleeve are worn replace the valve and sleeve. 8. Remove and inspect the (A) inner and the (B) outer gerotor gears. 1. Clean all pump parts in solvent. 2. Dry the parts with compressed air. 3. Inspect the pump gears, faces, gear teeth, pump housing and mating surfaces for damage or scoring. 4. Replace the entire pump if any part is damaged or worn. 9. Inspect the (A) converter hub bushing. If scored or excessively worn, replace the entire pump. Note the orientation of the (B) lube groove. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 5142 10. Inspect the (A) front and the (B) rear input shaft bushings. If scored or worn, replace the entire pump. 11. Measure and record the depth of the inner, then the outer, pump gerotor gear face-to-pump body machined surface. 1. Place the pump gerotor gear set into the pump gear pocket and center it to the pump bushing diameter. 2. Using a depth micrometer, measure and record the depth of the inner gerotor gear face to the pump body machined surface. Repeat measurement for a total of three readings in equally spaced locations on the gear face. If the reading is not within specification, replace the front pump assembly. 3. Remove the (A) inner gear and reinstall the (B) outer gear. Repeat Substep 2 for the outer gerotor gear face. 12. Inspect the following: - All valve and plug bores for scoring or damage. - All passages for obstructions. - Mating surfaces for burrs and scoring, - All springs for distortion. - When dry, check all valves and plugs for free movement in their respective bores. ASSEMBLY 1. Install the (A) main regulator valve and sleeve assembly, the (B) converter clutch shift valve assembly, and the (C) converter regulator valve assembly. 1. Install the (A) main regulator boost valve and sleeve assembly. Then, apply pressure to the (D) main regulator booster sleeve and install the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 5143 (E) retainer, making sure it is properly seated. 2. Install the (B) converter clutch shift valve assembly. Then, apply pressure to the (F) end plug and install the (G) retainer, making sure it is properly seated. 3. Install the (C) converter regulator valve assembly. Then, apply pressure to the (H) end plug and install the (J) retainer, making sure it is properly seated. 2. Install the (A) gerotor gear set, with the (B) dot facing the control body assembly. NOTE: Prior to installation, lightly lubricate the gerotor gears with clean MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. 3. Lower the (A) control body and stator assembly onto the (B) pump body, aligning the (C) 28 mm hole in each body. CAUTION: Prior to pump assembly, make sure all cup plugs are installed. CAUTION: Inspect mating surfaces of the pump body and the control body to make sure they are clean and free of nicks and burrs. 4. Assemble the pump. 1. Loosely install the 11(A) M8x50 bolts and the (B) 10 mm alignment bolt. 2. Install the Pump Banding Tool, with the (C) clamp positioned by the (D) filter inlet. 3. Align the (E) outer bolt holes and tighten the (F) Pump Banding Tool. 4. Tighten the 11(A) pump bolts and remove the (B) 10 mm alignment bolt. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 5144 - Remove the Pump Banding Tool. - Make sure the outer edges of the control body and the pump body are completely aligned. 5. Install the 2 coast clutch Teflon seals. Make sure the seals are fully seated in the stator support seal grooves and the (D) seal ends are oriented 180 degrees apart. CAUTION: Make sure the (A) seal grooves in the stator support are clean and free of burrs. CAUTION: Make sure the (B) seal ends are properly positioned together and not (C) separated. 6. Install the pump outer diameter square-cut front pump seal. 7. Install the front pump stator support seal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 5145 8. Install the new spring and stop assembly. CAUTION: Failure to replace these parts may cause repeat repairs. NOTE: Install the rubber stop end into the bore first. 9. Using a small drift and mallet, install the new orifice cup plug. NOTE: Make sure the edge of the cup plug is seated just below the stator support surface that mates with the No. 2 needle bearing assembly. 10. If removed, install the front pump seal, using the Front Pump Seal Replacer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 5146 11. Install the (A) No.1 pump thrust washer and the (B) No. 2A overdrive sun gear thrust bearing. NOTE: Lightly lubricate the thrust washer and the bearing with petroleum jelly to hold them in place during assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Intermediate Shaft, A/T > Component Information > Specifications Intermediate Shaft: Specifications Intermediate/Overdrive cylinder Fluid Feed Bolt .............................................................................................................................. 8-14 Nm (6-10 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Intermediate Shaft, A/T > Component Information > Specifications > Page 5150 Intermediate Shaft: Service and Repair Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Intermediate Shaft, A/T > Component Information > Specifications > Page 5151 DISASSEMBLY 1. Using the (A) Clutch Spring Compressor Plate, the (B) Clutch Spring Compressor Bar and the (C) Clutch Spring Compressor Plate, compress the overdrive clutch piston return spring. 2. Remove the overdrive clutch piston return spring retainer. Remove the tools. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Intermediate Shaft, A/T > Component Information > Specifications > Page 5152 3. Remove the overdrive clutch piston return spring. 4. Remove the overdrive clutch piston. NOTE: The overdrive piston seals are bonded to the piston. If the seals are damaged, replace the piston assembly. 5. Remove the intermediate clutch piston. 6. Using the O-Ring Tool, remove the intermediate clutch piston inner seal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Intermediate Shaft, A/T > Component Information > Specifications > Page 5153 7. Using the O-Ring Tool, remove the intermediate clutch piston outer seal. ASSEMBLY 1. Install the intermediate clutch piston outer seal, with the lip seal facing upward. NOTE: Prior to reassembly, inspect the check ball, the cup plugs and the feed bolt threads for contamination or damage. Clean or replace, as necessary. 2. Install the intermediate clutch piston inner seal, with the lip seal facing downward toward the cylinder. 3. Install the intermediate clutch piston. NOTE: The piston should rotate freely in the cylinder. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Intermediate Shaft, A/T > Component Information > Specifications > Page 5154 4. Position the (A) overdrive clutch piston onto the (B) intermediate/overdrive cylinder at a slight angle. Then, rotate the piston while pressing it down until fully seated onto the cylinder. CAUTION: The overdrive piston lip seals are bonded to the piston. Use care not to damage or roll the lip seal over. NOTE: Coat the inner and the outer lip seals with petroleum jelly. 5. Install the overdrive clutch piston return spring. NOTE: The overdrive clutch piston return spring must be installed with fingers facing upward. 6. Using the (A) Clutch Spring Compressor Plate, the (B) Clutch Spring Compressor Bar and the (C) Clutch Spring Compressor Plate, compress the overdrive clutch piston return spring. 7. Install the overdrive clutch piston return spring retainer. Make sure the retainer is fully seated, then remove the tools. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection For testing procedures for the Transmission Control Indicator Lamp (TCIL), please refer to Pinpoint Test C in Automatic Transmission/Transaxle / Testing and Inspection / Procedures / External Control Diagnostics. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Place the transmission range selector lever into MANUAL 1 position, then back to the (D) position. 2. Hang a three-pound weight on the transmission range selector lever. 3. Center the pointer in the middle of the (D) position. - Rotate the thumb wheel, located on the bottom of the steering column, to adjust the pointer. 4. Remove the weight. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Testing and Inspection Output Shaft: Testing and Inspection 1. Inspect the output shaft for wear. Make sure the (B) cup plug orifice and lube passages through output shaft are clean and free of debris. Replace as required. CAUTION: Build-up of contamination can block the flow of lubricant behind the cup plug and cause transmission assembly damage. NOTE: The (A) anti-seepage seal is intended for shipping purposes only. It is not necessary to remove and reuse this seal when replacing the output shaft. NOTE: The output shaft cannot be disassembled and must be replaced if damaged. 2. Inspect the bearing surfaces of the output shaft for wear or scores. If excessive wear or scores are found, replace output shaft and inspect mating components. 3. Check the splines on the output shaft for wear. Replace the output shaft if the splines are excessively worn. Inspect all the bushings for wear. Replace if worn or damaged. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection For testing procedures for the Transmission Control Indicator Lamp (TCIL), please refer to Pinpoint Test C in Automatic Transmission/Transaxle / Testing and Inspection / Procedures / External Control Diagnostics. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Description and Operation Overdrive Switch: Description and Operation The Transmission Control Switch (TCS) and Transmission Control Indicator Lamp (TCIL) are located inside the end of the gearshift lever. Pushing the TCS will either disengage or engage the overdrive function of the transmission. When overdrive is disengaged, the TCIL will illuminate the word OFF. Each time the ignition switch is placed in the RUN position, the transmission will automatically provide overdrive operation regardless of TCS position the last time the vehicle was running. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Description and Operation > Page 5171 Overdrive Switch: Testing and Inspection For testing procedures for the Transmission Control Switch (TCS), please refer to Pinpoint Test C in Automatic Transmission/Transaxle / Testing and Inspection / Procedures / External Control Diagnostics. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair Parking Pawl: Service and Repair REMOVAL NOTE: For internal park mechanism service. 1. Remove the extension housing and the extension housing gasket. 2. Remove the (A) bolts and the (B) parking rod guide plate. 3. Remove the (A) parking pawl return spring, the (B) parking pawl and the (C) parking pawl shaft. INSTALLATION 1. Install the (A) parking pawl shaft, the (B) parking pawl and the (C) parking pawl return spring with the spring end resting on the inside of the case. 2. Install the (A) parking rod guide plate with the (B) bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5175 NOTE: Make sure the dimple on the parking guide support plate is facing inward and the parking pawl actuating rod is in the parking rod support plate slot. 3. Install the extension housing gasket and the extension housing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Forward Planet Assembly Planetary Gears: Service and Repair Forward Planet Assembly DISASSEMBLY NOTE: Individual parts of the planet assemblies are not repairable. 1. Remove the No. 9B forward clutch thrust bearing. 2. Remove the No. 10A forward planet assembly thrust bearing. - The pins and shafts in the plant assemblies should be checked for loose fit/damage. Use a new planet assembly if either condition exist. - Inspect the pinion gears for damaged or excessively worn teeth. - Check for free rotation of the pinion gears. - Check for damage in the overdrive planet assembly. ASSEMBLY 1. Follow the removal procedure in reverse order. - Lightly lubricate the thrust bearing with petroleum jelly to hold it in place during assembly. - The No. 9B thrust bearing must be installed with the notched inner race facing outward. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Forward Planet Assembly > Page 5180 Planetary Gears: Service and Repair Reverse Planet Assembly DISASSEMBLY NOTE: Individual parts of the planet assemblies are not repairable. 1. Remove the No. 11 rear reverse planet thrust washer. 2. Remove the No. 1OB front reverse planet thrust washer. - The pins and shafts in the planet assemblies should be checked for loose fit/damage. Use a new planet assembly if either condition exists. - Inspect the pinion gears for damaged or excessively worn teeth, - Check for free rotation of the pinion gears. - Check for damage in the overdrive planet assembly. ASSEMBLY 1. Follow the removal procedure in reverse order. - Lightly lubricate the thrust washers with petroleum jelly to hold them in place during assembly. - The tabs on the thrust washers must engage the slots on the reverse planet assembly when installed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair Seals and Gaskets: Service and Repair Special Tools Special Tools REMOVAL 1. Raise and support the vehicle. 2. Remove the driveshaft. 3. With a suitable drain pan properly positioned, remove the (A) extension housing seal, using the (B) Seal Remover and the (C) Impact Slide Hammer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Page 5184 4. Using the (A) Extension Housing Bushing Remover, remove the (B) extension housing bushing. CAUTION: Do not damage any machined surfaces. The new seal may leak. INSTALLATION 1. Align the extension housing bushing in the extension housing so that the slots are in the 2 o'clock and 7 o'clock positions. CAUTION: Prior to installing the extension housing bushing, inspect the extension housing counterbore for burrs. If necessary, remove the burrs with an oil stone. Damage to new bushing may occur. 2. Using the (A) Extension Housing Bushing Replacer, install the (B) extension housing bushing. 3. Align the (A) extension housing seal in the extension housing, with the (B) drain hole positioned downward. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Page 5185 4. Using the (A) Extension Housing Seal Replacer, seat the extension housing seal into the (B) extension housing. 5. Install the driveshaft. 6. Remove the supports and lower the vehicle. 7. Fill the transmission to the specified level with MERCON(R) Automatic Transmission Fluid XT-2-QM or MERCON(R) V equivalent. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation Overdrive Switch: Description and Operation The Transmission Control Switch (TCS) and Transmission Control Indicator Lamp (TCIL) are located inside the end of the gearshift lever. Pushing the TCS will either disengage or engage the overdrive function of the transmission. When overdrive is disengaged, the TCIL will illuminate the word OFF. Each time the ignition switch is placed in the RUN position, the transmission will automatically provide overdrive operation regardless of TCS position the last time the vehicle was running. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Page 5190 Overdrive Switch: Testing and Inspection For testing procedures for the Transmission Control Switch (TCS), please refer to Pinpoint Test C in Automatic Transmission/Transaxle / Testing and Inspection / Procedures / External Control Diagnostics. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Mode Switch: Service and Repair TRANSMISSION MODE SWITCH REMOVAL 1. Remove the Transmission Control (TC) switch. 1. Remove the TC switch cover. 2. Remove the TC switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor .............................................................................................................................................. 8-10 Nm (75-85 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5197 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5198 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5199 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5200 Transmission Position Switch/Sensor: Service and Repair Special Tools REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1. Remove the bolts. 2. Remove the sensor. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5201 1. Install the digital transmission range (TR) sensor. 1. Install the sensor. 2. Loosely install the bolts. 2. Install the Digital Transmission Range (TR) Sensor Alignment Tool. NOTE: Make sure that the manual control lever is in the neutral position. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5202 5. Reconnect the connector. 6. Reconnect the battery ground cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Sensor Transmission Speed Sensor: Locations Output Shaft Speed Sensor Transmission View The Output Shaft Speed Sensor is located under the vehicle, on left side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Sensor > Page 5207 Transmission Speed Sensor: Locations Turbine Speed Sensor The Turbine Shaft Speed Sensor is located under the vehicle, on right side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5208 Output Shaft Speed Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications TORQUE SPECIFICATIONS Brake Shift Interlock Solenoid Bolts ........................................................................................................................................ 7-11 Nm (62-97 inch lbs.) Shift Lock Actuator Bolts ......................................................................................................................................................... 7-11 Nm (62-97 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5213 Shift Interlock Solenoid: Service and Repair REMOVAL 1. Disconnect the battery. WARNING: ON VEHICLES EQUIPPED WITH AN AUXILIARY BATTERY, BOTH THE NEGATIVE AND POSITIVE BATTERY CABLES MUST BE DISCONNECTED. WARNING: ON VEHICLES EQUIPPED WITH A 7.3L, ENGINE, BOTH THE PRIMARY AND SECONDARY BATTERIES MUST BE DISCONNECTED. 2. Remove the instrument panel steering column cover, the driver side knee brace and the instrument panel steering column opening cover reinforcement. 3. Disconnect all necessary harness connectors and separate the harness bracket from the steering column. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5214 4. Remove the shift indicator cable and position it aside. 5. Remove the nuts and lower the steering column. 6. Remove the shift lock actuator and disconnect the harness connector. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5215 1. Follow the removal procedure in reverse order. 2. Make sure the shift cable and the shift indicator cable are properly adjusted. Verify shift lock actuator operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair Shifter A/T: Service and Repair REMOVAL 1. Remove the instrument panel cluster opening finish panel assembly. 2. Remove the ignition switch lock cylinder. 1. Position the lock cylinder to RUN. 2. Using a suitable tool, push upward on the cylinder release tab through the hole in the lower shroud while pulling the cylinder outward. 3. Remove the upper steering column shroud. 4. Remove the transmission range selector lever. Disconnect the electrical connector. INSTALLATION 1. Follow the removal procedure in reverse order. NOTE: The transmission range selector lever pin must be replaced whenever it is removed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair Selector Shaft: Service and Repair REMOVAL 1. Disconnect the battery ground cable. WARNING: ON VEHICLES EQUIPPED WITH AN AUXILIARY BATTERY, BOTH THE NEGATIVE AND POSITIVE BATTERY CABLES MUST BE DISCONNECTED. WARNING: ON VEHICLES EQUIPPED WITH A 7.3L ENGINE, BOTH THE PRIMARY AND SECONDARY BATTERIES MUST BE DISCONNECTED. 2. Raise and support the vehicle. 3. Disconnect the shift cable at the manual control lever shaft assembly. 4. Disconnect the connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > Page 5223 5. Remove the (A) bolts and the (B) digital transmission range (TR) sensor. 6. With a suitable drain pan properly positioned, drain, then remove the transmission fluid pan and remove the gasket. 1. Loosen, but do not remove, the 20 fluid pan-to-case retaining bolts. 2. Remove the 15 front and side fluid pan-to-case retaining bolts. 3. Lower the front of the fluid pan and allow the fluid to drain. 4. With the fluid pan properly supported, remove the (A) bolts and the (B) fluid pan and gasket. CAUTION: Do not discard the gasket unless damaged. This is a reusable gasket. 7. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary. NOTE: After removal, discard the filter and seal assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > Page 5224 8. If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore. CAUTION: Be careful not to scratch or damage the aluminum bore or the new seal may leak. 9. Using the (A) Lock Nut Pin Remover, remove the (B) manual lever shaft retaining pin. NOTE: A No. 53 drill bit (1/16 inch) can be used instead to remove the manual lever shaft retaining pin. 10. Remove the (A) nut, the (B) inner manual valve detent lever, the (C) parking pawl actuating rod and the (D) manual control lever shaft assembly. CAUTION: Be careful not to damage the manual control lever bore. NOTE: The manual control lever and manual control lever shaft are one piece. NOTE: Use a crescent wrench on the manual control lever or outer flats of manual control lever shaft assembly when removing the inner manual valve detent lever nut. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > Page 5225 11. Using the (A) Puller, remove the (B) manual control lever seal,. INSTALLATION 1. Using the (A) Shift Lever Seal Replacer, install the (B) manual control lever seal. NOTE: Prior to installing the manual control lever seal, clean the bore opening with mineral spirits. 2. Install the manual control lever shaft assembly. 1. Install the manual control lever shaft assembly. 2. Install and seat the manual lever shaft retaining pin below the case surface. 3. Install the (A)parking pawl actuating rod and the (B) inner manual valve detent lever. NOTE: The inner manual valve detent lever must be seated on the flats of the manual control lever shaft assembly, and the parking pawl actuating rod must be through the guide plate. NOTE: The manual control valve detent lever spring must be on the inner manual valve detent lever, and the detent lever pin must align with the manual shift valve. 4. Install the inner manual valve detent lever nut. NOTE: Use a crescent wrench on the manual control lever or the outer flats of the manual control lever shaft assembly when installing the inner manual valve detent lever nut. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > Page 5226 3. Press the fluid filter and seat assembly into the pump bore until seated. NOTE: Prior to installation,lightly lubricate seal with clean MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. 4. Position the (A) gasket onto the cleaned fluid pan. Make sure the (B) magnet is positioned over the dimple in the fluid pan. NOTE: Apply a light coat of petroleum jelly to hold the gasket to the fluid pan. 5. Install the (A) pan with the gasket. Alternately tighten the 20 (B) bolts. 6. Install the digital Transmission Range (TR) sensor. 1. Install the digital TR sensor. 2. Loosely install the bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > Page 5227 7. Install the Digital Transmission Range (TR) Sensor Alignment Tool. 8. Tighten the bolts. 9. Connect the connector. 10. Connect the shift cable to the manual control lever shaft assembly. 11. Remove the supports and lower the vehicle. 12. Connect the battery ground cable. 13. Fill the transmission to the specified level with MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications Shift Cable: Specifications Shift Cable Bracket Nut ......................................................................................................................................................... 16-20 Nm (12-15 ft. lbs.) Shift Cable Bracket Bolts, 4R70W Transmission: with 4.6L Engine .............................................................................................................................................................. 23-32 Nm (17-24 ft. lbs.) with 4.2L Engine .......................................................................................... ........................................................................ 27-41 Nm (20-30 ft. lbs.) Shift Cable Bracket Bolts E40D Transmission .......................................................................................................................................................... 27-41 Nm (20-30 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5231 Shift Cable: Adjustments NOTE: The 4R70W transmission is shown, this procedure is also used for the E40D transmission. 1. Place the transmission range selector lever in the (D) position. - Place a three-pound weight on the transmission range selector lever. 2. Raise and support the vehicle. 3. Disconnect the shift cable at the manual control lever. 4. Unlock the lock tab on the transmission shift cable. 5. Verify the manual control lever is in the Overdrive position. 1. Place the manual control lever in the first gear position. 2. Move the manual control lever two detents to the Overdrive position. 6. Connect the transmission shift cable to the manual control lever. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5232 7. Lock the shift cable lock tab. 8. Lower the vehicle. 9. Remove the three-pound weight. 10. Carefully move the transmission range selector lever from detent to detent and compare with the transmission settings. - Readjust if necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5233 Shift Cable: Service and Repair REMOVAL NOTE: The 4R70W transmission is shown, this procedure is also used for the E40D transmission. 1. Disconnect the shift cable. 2. Push the rubber grommet and the transmission shift cable through the bulkhead. 3. Raise and support the vehicle. 4. Remove the shift cable. 1. Disconnect the cable at the manual control lever. 2. Press the lock tabs and remove the cable from the bracket. 5. Remove the shift cable bracket (all except vehicles equipped with 4.2L engine). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5234 6. Remove the shift cable bracket (vehicles equipped with 4.2L engine). 1. Remove the bolt. 2. Remove the nut. 3. Remove the bracket. INSTALLATION 1. Follow the removal procedure in reverse order. - Adjust the shift cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > Recalls for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall Incorrect Speedometer Gear Installed Technical Service Bulletin # 98S28 Date: 990201 Recall - Incorrect Speedometer Gear Installed 98928 SAFETY RECALL Certain 1999 Econoline Vans for Speedometer Driven Gear and Instrument Cluster Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > Recalls for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall Incorrect Speedometer Gear Installed > Page 5243 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list ^ Other eligible vehicles which are brought to your dealership Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > Recalls for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall Incorrect Speedometer Gear Installed > Page 5244 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted ^ does not make a service date CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. REFUNDS See Section 3 of the ACESII Manual. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information 1. Speedometer driven gear must be ordered first. Call the Recall Hotline at 1-800-325-5621. The gears will be sent free of charge. Be prepared to provide the VIN and mileage for the vehicle being serviced and your Parts and Accessories code to the Hotline Analyst. When the gear is ordered the Recall Hotline will calculate the proper mileage for the vehicle. The mileage given to you by the Recall Hotline should be given to the Instrument Cluster Order Center as described below. 2. Instrument Cluster must be ordered second. Call the Instrument Cluster Order Center at 1-800-259-9700. All orders and questions for instrument clusters should be directed to this order center. Do not order a cluster using the existing mileage on the customer's vehicle. Use only the calculated mileage given to you by the Recall Hotline when the speedometer driven gear was ordered. Instrument Cluster Part Numbers: The old cluster should be handled according to instructions that will be sent with the new cluster. NOTE: The speedometer driven gear and the instrument cluster will be shipped to arrive the next day as long as the order is received before 2:00 p.m. Eastern Time. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > Recalls for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall Incorrect Speedometer Gear Installed > Page 5245 DEALER PRICE Speedometer gears will be shipped no charge to dealers. For latest prices on instrument clusters, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book Attachment III - Technical Information SPEEDOMETER DRIVEN GEAR REPLACEMENT AFFECTED VEHICLES: 1999 ECONOLINE ORDERING NEW INSTRUMENT CLUSTER 1. Obtain the Vehicle Identification Number (VIN) and mileage from the vehicle being serviced. 2. Call the Recall Hotline at 1-800-325-5621 to order the speedometer driven gear and obtain the corrected mileage. After providing your Parts and Accessories Code, the VIN, and the mileage, the recall hotline will provide you with the color of the speedometer driven gear that will be sent for this vehicle and the corrected mileage. Record the gear color and corrected mileage on the repair order. 3. Call the Instrument Cluster Ordering Center at 1-800-259-9700. Provide the service center with the VIN and corrected mileage. When the new instrument cluster and gear arrive, complete the Service Procedure. SERVICE PROCEDURE 1. Verify speedometer driven gear is the correct color. This should have been recorded on the repair order when the speedometer gear order was placed. If the gear is not the correct color, call Recall Hotline at 1-800-325-5621 to order the correct gear. 2. Install memory saver, then disconnect battery negative cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > Recalls for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall Incorrect Speedometer Gear Installed > Page 5246 3. Remove headlamp switch knob and bezel. Refer to Figure 1. 4. Remove left instrument panel finish panel. See Figure 1. 5. Remove instrument cluster retaining screws. 6. Remove instrument cluster lens. See Figure 2. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > Recalls for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall Incorrect Speedometer Gear Installed > Page 5247 7. Unclip PRNDL indicator from instrument cluster, then position indicator away from cluster. See Figure 3. 8. Pull instrument cluster away from instrument panel, then disconnect cluster electrical connectors. 9. Remove instrument cluster from vehicle. 10. Connect electrical connectors to new instrument cluster. 11. Connect battery negative cable. 12. Turn ignition switch to ON position. Do not start engine. 13. Verify instrument cluster displays the corrected mileage. This should have been recorded on the repair order when the speedometer gear order was placed. It corrected mileage is not displayed, call Instrument Cluster Ordering Center at 1-800-259-9700 to order a new cluster with the corrected mileage. 14. Disconnect battery negative cable. 15. Install instrument cluster into instrument panel. 16. Clip PRNDL indicator onto instrument cluster. 17. Install instrument cluster lens. 18. Install instrument cluster retaining screws. Tighten screws to 2-3 N-m (18-27 lb-in). 19. Install left instrument panel finish panel. Tighten retaining screws securely. 20. Install headlamp switch knob and bezel. 21. Connect battery negative cable, then disconnect memory saver. 22. Prepare original instrument cluster for shipment back to service center. 23. Raise and support vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > Recalls for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall Incorrect Speedometer Gear Installed > Page 5248 24. Disconnect Vehicle Speed Sensor (VSS) electrical connector. Refer to Figure 4. 25. Remove VSS from transmission. See Figure 4. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > Recalls for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall Incorrect Speedometer Gear Installed > Page 5249 26. Remove speedometer driven gear retaining clip. See Figure 5. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > Recalls for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall Incorrect Speedometer Gear Installed > Page 5250 27. Slide speedometer driven gear oft of vehicle speed sensor. See Figure 6. 28. Install replacement driven gear on VSS. 29. Install driven gear retaining clip. 30. Clean VSS 0-ring. 31. Install VSS in transmission. Tighten retaining bolt to 4-6 Nm (36-53 lb-in). 32. Lower vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > Recalls for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall Incorrect Speedometer Gear Installed > Page 5251 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > Recalls for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall Incorrect Speedometer Gear Installed > Page 5252 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall - Incorrect Speedometer Gear Installed Technical Service Bulletin # 98S28 Date: 990201 Recall - Incorrect Speedometer Gear Installed 98928 SAFETY RECALL Certain 1999 Econoline Vans for Speedometer Driven Gear and Instrument Cluster Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall - Incorrect Speedometer Gear Installed > Page 5258 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list ^ Other eligible vehicles which are brought to your dealership Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall - Incorrect Speedometer Gear Installed > Page 5259 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted ^ does not make a service date CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. REFUNDS See Section 3 of the ACESII Manual. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information 1. Speedometer driven gear must be ordered first. Call the Recall Hotline at 1-800-325-5621. The gears will be sent free of charge. Be prepared to provide the VIN and mileage for the vehicle being serviced and your Parts and Accessories code to the Hotline Analyst. When the gear is ordered the Recall Hotline will calculate the proper mileage for the vehicle. The mileage given to you by the Recall Hotline should be given to the Instrument Cluster Order Center as described below. 2. Instrument Cluster must be ordered second. Call the Instrument Cluster Order Center at 1-800-259-9700. All orders and questions for instrument clusters should be directed to this order center. Do not order a cluster using the existing mileage on the customer's vehicle. Use only the calculated mileage given to you by the Recall Hotline when the speedometer driven gear was ordered. Instrument Cluster Part Numbers: The old cluster should be handled according to instructions that will be sent with the new cluster. NOTE: The speedometer driven gear and the instrument cluster will be shipped to arrive the next day as long as the order is received before 2:00 p.m. Eastern Time. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall - Incorrect Speedometer Gear Installed > Page 5260 DEALER PRICE Speedometer gears will be shipped no charge to dealers. For latest prices on instrument clusters, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book Attachment III - Technical Information SPEEDOMETER DRIVEN GEAR REPLACEMENT AFFECTED VEHICLES: 1999 ECONOLINE ORDERING NEW INSTRUMENT CLUSTER 1. Obtain the Vehicle Identification Number (VIN) and mileage from the vehicle being serviced. 2. Call the Recall Hotline at 1-800-325-5621 to order the speedometer driven gear and obtain the corrected mileage. After providing your Parts and Accessories Code, the VIN, and the mileage, the recall hotline will provide you with the color of the speedometer driven gear that will be sent for this vehicle and the corrected mileage. Record the gear color and corrected mileage on the repair order. 3. Call the Instrument Cluster Ordering Center at 1-800-259-9700. Provide the service center with the VIN and corrected mileage. When the new instrument cluster and gear arrive, complete the Service Procedure. SERVICE PROCEDURE 1. Verify speedometer driven gear is the correct color. This should have been recorded on the repair order when the speedometer gear order was placed. If the gear is not the correct color, call Recall Hotline at 1-800-325-5621 to order the correct gear. 2. Install memory saver, then disconnect battery negative cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall - Incorrect Speedometer Gear Installed > Page 5261 3. Remove headlamp switch knob and bezel. Refer to Figure 1. 4. Remove left instrument panel finish panel. See Figure 1. 5. Remove instrument cluster retaining screws. 6. Remove instrument cluster lens. See Figure 2. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall - Incorrect Speedometer Gear Installed > Page 5262 7. Unclip PRNDL indicator from instrument cluster, then position indicator away from cluster. See Figure 3. 8. Pull instrument cluster away from instrument panel, then disconnect cluster electrical connectors. 9. Remove instrument cluster from vehicle. 10. Connect electrical connectors to new instrument cluster. 11. Connect battery negative cable. 12. Turn ignition switch to ON position. Do not start engine. 13. Verify instrument cluster displays the corrected mileage. This should have been recorded on the repair order when the speedometer gear order was placed. It corrected mileage is not displayed, call Instrument Cluster Ordering Center at 1-800-259-9700 to order a new cluster with the corrected mileage. 14. Disconnect battery negative cable. 15. Install instrument cluster into instrument panel. 16. Clip PRNDL indicator onto instrument cluster. 17. Install instrument cluster lens. 18. Install instrument cluster retaining screws. Tighten screws to 2-3 N-m (18-27 lb-in). 19. Install left instrument panel finish panel. Tighten retaining screws securely. 20. Install headlamp switch knob and bezel. 21. Connect battery negative cable, then disconnect memory saver. 22. Prepare original instrument cluster for shipment back to service center. 23. Raise and support vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall - Incorrect Speedometer Gear Installed > Page 5263 24. Disconnect Vehicle Speed Sensor (VSS) electrical connector. Refer to Figure 4. 25. Remove VSS from transmission. See Figure 4. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall - Incorrect Speedometer Gear Installed > Page 5264 26. Remove speedometer driven gear retaining clip. See Figure 5. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall - Incorrect Speedometer Gear Installed > Page 5265 27. Slide speedometer driven gear oft of vehicle speed sensor. See Figure 6. 28. Install replacement driven gear on VSS. 29. Install driven gear retaining clip. 30. Clean VSS 0-ring. 31. Install VSS in transmission. Tighten retaining bolt to 4-6 Nm (36-53 lb-in). 32. Lower vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall - Incorrect Speedometer Gear Installed > Page 5266 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, A/T: > 98S28 > Feb > 99 > Recall - Incorrect Speedometer Gear Installed > Page 5267 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip Sun Gear: Technical Service Bulletins A/T - 4R70W Needle Bearing/Race Kit Service Tip Article No. 03-26-1 01/12/04 TRANSMISSION - 4R70W - NEW SERVICE PART - NUMBER 5 NEEDLE BEARING AND RACE KIT - SERVICE TIP FORD: 1994-1997 THUNDERBIRD, 1994-2003 CROWN VICTORIA, MUSTANG, E SERIES 1996-2001 EXPLORER 1994-2003 F SERIES LINCOLN: 1994-1998 MARK VIII 1994-2003 TOWN CAR MERCURY: 1994-1997 COUGAR 1994-2003 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE Should repairs become necessary on a 4R70W transmission involving replacement of the forward or reverse clutch sungear, and/or the number five (# 5) thrust bearing, these service pants all must be replaced in combination. A mismatch of service parts may cause an internal noise or a loss of forward and/or reverse. A new service kit has been produced to eliminate the mismatch of service pants. This new kit services all 4R70W transmissions built prior to the 2004 model. ACTION A new Service Kit 4L3Z-7D234-M has been produced to eliminate the mismatch of service parts. The kit contains the following: ^ A new two (2) piece number five (# 5) thrust bearing assembly (70234 bearing and 70235 race) (Figure 1) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 5272 ^ A forward clutch sun gear (7A399) (Figure 2) ^ A reverse sun gear (7A019) (Figure 3) SERVICE TIP To install, refer to the latest version Workshop Manual for disassembly and reassembly of the transmission. CAUTION ALL COMPONENTS IN THE KIT MUST BE INSTALLED OR THE REPAIR MAY NOT BE EFFECTIVE AND MAY CAUSE AN INTERNAL NOISE OR LOSS OF FORWARD AND~OR REVERSE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 5273 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Page 5274 Sun Gear: Service and Repair INPUT SHELL Disassembly 1. Remove and discard the forward/reverse sun gear retaining ring. 2. Remove the No. 14 input shell thrust washer. 3. Remove the forward/reverse sun gear. Assembly 1. Follow the removal procedure in reverse order. - Install the sun gear with the lube hole between the stand-off pads on the input shell. - Use care not to overextend the new retaining ring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip Thrust Washer/Bearing: Technical Service Bulletins A/T - 4R70W Needle Bearing/Race Kit Service Tip Article No. 03-26-1 01/12/04 TRANSMISSION - 4R70W - NEW SERVICE PART - NUMBER 5 NEEDLE BEARING AND RACE KIT - SERVICE TIP FORD: 1994-1997 THUNDERBIRD, 1994-2003 CROWN VICTORIA, MUSTANG, E SERIES 1996-2001 EXPLORER 1994-2003 F SERIES LINCOLN: 1994-1998 MARK VIII 1994-2003 TOWN CAR MERCURY: 1994-1997 COUGAR 1994-2003 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE Should repairs become necessary on a 4R70W transmission involving replacement of the forward or reverse clutch sungear, and/or the number five (# 5) thrust bearing, these service pants all must be replaced in combination. A mismatch of service parts may cause an internal noise or a loss of forward and/or reverse. A new service kit has been produced to eliminate the mismatch of service pants. This new kit services all 4R70W transmissions built prior to the 2004 model. ACTION A new Service Kit 4L3Z-7D234-M has been produced to eliminate the mismatch of service parts. The kit contains the following: ^ A new two (2) piece number five (# 5) thrust bearing assembly (70234 bearing and 70235 race) (Figure 1) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 5279 ^ A forward clutch sun gear (7A399) (Figure 2) ^ A reverse sun gear (7A019) (Figure 3) SERVICE TIP To install, refer to the latest version Workshop Manual for disassembly and reassembly of the transmission. CAUTION ALL COMPONENTS IN THE KIT MUST BE INSTALLED OR THE REPAIR MAY NOT BE EFFECTIVE AND MAY CAUSE AN INTERNAL NOISE OR LOSS OF FORWARD AND~OR REVERSE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 5280 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges Torque Converter: Customer Interest A/T - Torque Converter Access Plug Dislodges Article No. 02-21-1 10/28/02 TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED FORD: 1989-1996 BRONCO 1989-1997 F SUPER DUTY 1989-1998 F-250 LD, F-53 MOTORHOME 1989-2003 E SERIES, F-150 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2003 EXCURSION LINCOLN: 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD ISSUE Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time and loading being applied to the plug during usage or cleaning of the underside of the vehicle. ACTION Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will till any gaps between the transmission case and the plug. SERVICE PROCEDURE 1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. 2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. 3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. 4. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation. PART NUMBER PART NAME PM-4 Motorcraft Brake Parts Cleaner E9TZ-7N171-A Plug - Converter Access F7TZ-19554-AA Ultra Silicone Sealant OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022101A Install Torque Converter 0.2 Hr. Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 5289 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges Torque Converter: All Technical Service Bulletins A/T - Torque Converter Access Plug Dislodges Article No. 02-21-1 10/28/02 TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED FORD: 1989-1996 BRONCO 1989-1997 F SUPER DUTY 1989-1998 F-250 LD, F-53 MOTORHOME 1989-2003 E SERIES, F-150 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2003 EXCURSION LINCOLN: 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD ISSUE Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time and loading being applied to the plug during usage or cleaning of the underside of the vehicle. ACTION Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will till any gaps between the transmission case and the plug. SERVICE PROCEDURE 1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. 2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. 3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. 4. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation. PART NUMBER PART NAME PM-4 Motorcraft Brake Parts Cleaner E9TZ-7N171-A Plug - Converter Access F7TZ-19554-AA Ultra Silicone Sealant OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022101A Install Torque Converter 0.2 Hr. Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 5295 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 5296 Torque Converter: Specifications Torque Converter Drain Plug ...................................................................................................................................................... 28.5-31 Nm (21-22 ft. lbs.) Flywheel to Torque Converter ....................................................................................................................................................... 30-41 Nm (22-30 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 5297 Torque Converter: Description and Operation The torque converter transmits and multiplies torque. The torque converter is a four-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 fluid in motion. - The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain through the input shaft. - The reactor redirects fluid going back into the impeller, providing 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 gear sets and other components through the input shaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Torque Converter: Initial Inspection and Diagnostic Overview 1. If the torque converter is being replaced, continue with sub-step 2 of Step 2. 2. If the torque converter is not being replaced the following procedures must be performed: 1. The torque converter must be thoroughly cleaned. - Torque converters with drain plugs may be cleaned by using the Torque Converter/Oil Cooler Cleaner. - Torque converters without drain plugs may be cleaned by hand. Partially fill the torque converter using only the recommended transmission fluid for the applicable transmission. Hand-agitate the torque converter and then thoroughly drain the fluid. Refill the torque converter with new fluid specified for the transmission, and reinstall. 2. The in-tank and auxiliary coolers must be thoroughly cleaned by forward and backward flushing. 3. The cooler lines must be thoroughly cleaned by backward and forward flushing. 4. All Cooler Bypass Valves (CBV), if equipped, must be thoroughly cleaned. 5. Perform the Transmission Fluid Cooler Flow Test. 6. If the transmission cooling system fails the Transmission Fluid Cooler Flow Test, the fluid cooler, cooler bypass valve, and/or cooler lines must be replaced. 7. If the coolers or cooler by-pass valve are to be replaced use only factory-approved service parts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5300 Torque Converter: Component Tests and General Diagnostics End Play Check Special Tools 1. Install the End Play Checking Tool. 1. Insert the End Play Checking Tool fully into the torque converter pump drive. 2. Tighten until the inner post of tool is securely locked. 2. Attach the Dial Indicator with Bracketry to the End Play Checking Tool - Position the (A) indicator button between the ridges on the converter housing and zero the (B) dial. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5301 3. Lift up on the End Play Checking Tool as far as it will move and note the dial indicator reading. - If the reading exceeds end play limits, replace the torque converter. 4. Remove the dial indicator and tool. Leakage Checks Special Tools 1. Clean the outside surface of the torque converter. 2. Install the Torque Converter Leak Check Tool and Gasket into the converter hub. 3. Install the torque converter with the installed leak check tool into the Arbor press. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5302 Secure the press. Apply enough force from the press to seal the tool into the torque converter. WARNING: ALWAYS FOLLOW PROPER SAFETY PROCEDURES WHILE USING THE PRESS. 4. Apply air pressure to the valve on the leak check tool. NOTE: Use clean, dry shop air. 5. With air pressure applied to the valve, inspect for leaks at the converter hub, the seams and the studs. A soap bubble solution can be applied around those areas to aid in the diagnosis. If any leaks are present, replace the converter. 6. Remove the air hose. Release the pressure, and then slowly release the press. Remove the converter. Remove the tool. One-Way Clutch Check Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5303 Special Tools 1. Insert the Converter Clutch Holding Tool in one of the grooves in the stator thrust washer. 2. Install the Converter Clutch Torquing Tool in the converter pump drive. 3. Using (A) torque wrench, turn the (B) Converter Clutch Torquing Tool counterclockwise while holding the (C) Converter Clutch Holding Tool. - The converter one-way clutch should lock up and hold the specified torque. - The torque converter one-way clutch should rotate freely in the clockwise direction. - Try the clutch for lockup and hold in at least five positions. - If the clutch fails to lock up and hold the specified torque, replace the torque converter. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5304 Stator to Impeller Interference Check 1. Position the stator support with the splines up. CAUTION: To perform this check, do not use the pump stator support which will be installed in the transmission. Damage to the pump stator support, front pump seal or front pump stator seal may occur. NOTE: Obtain a scrapped pump. Remove the stator support. This can be used as a permanent tool to perform this check. 2. Mount the (A) torque converter on the (B) stator support so that the splines on the one-way clutch inner race engage the mating splines of the stator support. 3. Hold the stator support stationary and rotate the torque converter counterclockwise. - The torque converter should rotate freely, with no signs of scraping. - If there are signs of scraping, replace the torque converter. CAUTION: On diesel applications the torque converter with multi plate clutches may rattle and make some scraping noises. This is normal. Stator to Turbine Interference Check 1. Position the torque converter with the converter hub up. 2. Install a pump stator support, engaging the mating splines of the stator support shaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5305 3. Install the input shaft, engaging the splines with the turbine hub. 4. Hold the stator support stationary and attempt to rotate the turbine with the input shaft. - The turbine and lockup clutch assemblies should rotate in both directions, not exceeding the maximum torque shown, without any signs of metallic interference or scraping noise. 5. If interference exists, the stator front thrust washer may be worn, allowing the stator to hit the turbine, In such cases, the torque converter must be replaced. Check the converter crankshaft pilot for nicks or damaged surfaces that could cause interference when installing the torque converter into the crankshaft pilot. Check the converter front impeller hub for nicks or sharp edges that would damage the pump seal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Flushing Torque Converter: Service and Repair Flushing 1. Following the instructions included with the Torque Converter/Transmission Oil Cooler Cleaner, flush the torque converter. CAUTION: Mineral spirits used to clean the torque converter must be fresh, non-chlorinated and non-halogenated. 2. After flushing, drain the remainder of the solvent through the converter drain plug. 3. Add 1.9 liter (2 quart.) of clean MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent MERCON(R) V approved fluid into the converter fluid filler tube and agitate by hand. 4. Thoroughly drain the solution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Flushing > Page 5308 Torque Converter: Service and Repair Service and Replacement 1. The torque converter must be replaced if one or more of the following statements are true: - A torque converter malfunction has been determined based on the complete diagnostic procedures. - Converter stud(s), impeller hub or bushing is damaged. - Discoloration of the torque converter (due to overheating). - The torque converter is found to be out of specification when performing one of the following torque converter checks: One-Way Clutch Check - End Play Check - Stator to Turbine Interference Check - Stator to Impeller Interference Check - Torque Converter Leak Check - Evidence of transmission assembly or 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. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips Transmission Cooler: Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 5313 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 5314 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Oil Cooler, Transmission Transmission Cooler: Specifications Oil Cooler, Transmission Cooler Bypass Valve-to-Case Inlet ...................................................................................................................................................... ...................................... 27-33 Nm (20-24 ft. lbs.) Outlet .................................................................... ..................................................................................................................... 33-40 Nm (25-29 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Oil Cooler, Transmission > Page 5317 Transmission Cooler: Specifications Transmission Cooler Port 5/16-Inch Fluid Cooler Tube-ToCooler Bypass Valve ....................................................................................................................................................... 16-24 Nm (12-17 ft. lbs.) 3/8-Inch Fluid Cooler Tube-ToCooler Bypass Valve ........................................................................................................................................................ 24-30 Nm (18-22 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 5318 Transmission Cooler: Description and Operation E40d Transmission 4R70W Transmission All vehicles with automatic transmission are equipped with a transmission fluid cooler that is integral to the radiator assembly and cannot be repaired separately. In addition, an auxiliary transmission fluid cooler is mounted in front of the radiator. In operation, transmission fluid travels from the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 5319 transmission to the integral fluid cooler to the auxiliary transmission fluid cooler and back to the transmission. The integral transmission fluid cooler transfers heat from the transmission fluid to the engine coolant. The auxiliary transmission fluid cooler transfers heat from the transmission fluid to the outside air. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 When fluid leakage is found at any of the transmission fluid cooling components, the component must be replaced. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5322 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Cooler Port Transmission Cooler: Service and Repair Transmission Cooler Port Flushing and Cleaning 1. Remove the cooler bypass valve. 2. Using the Torque Converter/Oil Cooler Cleaner and adapter kit flush the transmission cooler bypass valve assembly. 3. Plug the cooler bypass valve front fitting with a 13 mm x 1.5 mm threaded plug. CAUTION: Make sure the cooler bypass valve is in the solvent tank before turning on the solvent. Also, make sure the fitting is pointed down so solvent does not spray upward out of the tank. NOTE: The solvent pressure must be a minimum of 50 psi to overcome the valve inside the cooler bypass tube and let solvent flow. Do not exceed 90 psi. 4. Place a 1/2 inch flat washer over the fitting that screws into the case out hole and connect the cleaner pressure line. 5. Place the cooler bypass valve into the solvent tank. Regulate the solvent pressure to between 50 and 90 psi. Turn on the solvent and circulate for 5 minutes. NOTE: The Torque Converter/Oil Cooler Cleaner can be switched on and off to help dislodge the contaminants. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Cooler Port > Page 5325 6. Disconnect all rubber hoses from the cooler bypass valve. 7. Use regulated compressed air to purge the cooler bypass valve of solvent. - Remove the plug from the cooler bypass valve. Replacement REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING, OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE RH KICK PANEL AREA. FAILURE TO INFLATION OF DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the front cooler tube from the front cooler bypass valve fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Cooler Port > Page 5326 3. Remove the rear cooler tube from the rear cooler bypass valve fitting. 4. Remove the front bolt. NOTE: The two rubber-coated sealing washers can fall out during removal of the front bolt. 5. Remove the rear bolt. NOTE: The two rubber-coated sealing washers can fall out during removal of the rear bolt. 6. Remove the cooler bypass valve. INSTALLATION 1. Examine the rubber-coated sealing washers. Replace the washers if damaged. CAUTION: Make sure the 4 rubber-coated sealing washers are on the cooler nuts and the cooler bypass valve washers are in place. Do not over tighten. 2. Using Thread lock and Sealer EOAZ-19554-AA or equivalent meeting Ford specifications coat the cooler bypass valve bolt threads. 3. Install the washers. NOTE: Align the two rubber-coated sealing washers while assembling the rear cooler bypass valve fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Cooler Port > Page 5327 4. Install the cooler bypass valve fitting bolts. CAUTION: If the cooler bypass valve bolt is over-tightened the rubber-coated sealing washers can be damaged, causing a transmission fluid leak. NOTE: Align the two rubber-coated sealing washers while assembling the front cooler bypass valve fitting. 5. Tighten the cooler tubes. 6. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 7. Fill the transmission with MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specifications MERCON(R) V ATF. Check for proper operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Cooler Port > Page 5328 Transmission Cooler: Service and Repair Oil Cooler, Transmission Backflushing and Cleaning CAUTION: Test the Torque Converter/Oil Cooler Cleaner to ensure that a vigorous fluid flow is present before proceeding. Replace the system filter if flow is weak or contaminated. 1. Connect the cleaner pressure and return lines appropriately. 1. Connect the pressure line to fluid cooler inlet tube. 2. Connect the return line to fluid cooler outlet tube. 3. Place the outlet end of the return line in the solvent tank reservoir. NOTE: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting them to the cleaner. 2. Switch the solvent pumps on. Allow the solvent to circulate a minimum of 5 minutes. NOTE: Cycling the solvent pump on and off will help dislodge contaminants in the cooler system. 3. Switch the solvent pump off. 4. Disconnect the cleaner pressure line at the fluid cooler tube. 5. Using compressed air, blow through the fluid cooler inlet tube until all solvent is removed. 6. Remove the rubber hoses from fluid cooler tubes. Cooler Bypass Valve REMOVAL 1. Raise and support the vehicle. 2. Remove the front cooler tube, from the front Cooler Bypass Valve (CBV) fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Cooler Port > Page 5329 3. Remove the rear cooler tube, from the rear CBV fitting. 4. Remove the front line case fitting. NOTE: The two rubber coated sealing washers can fall out during removal of the front line case fitting. 5. Remove the rear line case fitting. NOTE: The two rubber coated sealing washers can fall out during removal of the rear line case fitting. 6. Remove and clean the CBV. INSTALLATION 1. Examine the rubber coated sealing washers for damage. Replace the washers as needed. CAUTION: Make sure the 4 rubber coated sealing washers are on the cooler line case fittings and the CBV washers are in place. Do not over tighten. 2. Using Thread lock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 coat the line case fitting threads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Cooler Port > Page 5330 3. Install the line case fitting, CAUTION: Make sure the Cooler Bypass Valve (CBV) is properly back flushed. Use dry compressed air to remove solvent. CAUTION: If the cooler line case fitting is over-tightened the rubber coated sealing washers and/or cooler line case fittings can be damaged, causing a transmission fluid leak. NOTE: The CBV has a check ball in the rear fitting and will only allow flow in one direction. Make sure check ball moves freely. NOTE: Align the two rubber coated sealing washers, while assembling the rear CBV fitting. 4. Tighten the cooler tube nuts. 5. Lower the vehicle. 6. Fill the transmission with MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specifications MERCON(R) V . Check for proper operation. Removal and Installation REMOVAL 1. Remove the air cleaner assembly and the mounting bracket. 2. Remove the front radiator air deflector. 3. Remove the radiator grille. 4. If so equipped, remove the headlamp doors. 5. Remove the parking lamps. 6. Remove the radiator grille opening panel reinforcement. 7. Remove the hood latch. 8. With a suitable drain pan properly positioned, disconnect the fluid cooler hoses at the transmission fluid cooler. 9. Remove the transmission fluid cooler. INSTALLATION 1. Follow the removal procedure in reverse order. 2. Fill the transmission to the proper level and inspect for leaks. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair Transmission Mode Switch: Service and Repair TRANSMISSION MODE SWITCH REMOVAL 1. Remove the Transmission Control (TC) switch. 1. Remove the TC switch cover. 2. Remove the TC switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5338 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5339 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5340 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5341 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5342 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5343 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5344 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5345 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5346 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5347 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5348 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5349 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5351 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5352 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5353 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5354 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5355 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5356 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5357 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5358 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5359 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5360 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5361 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5362 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5363 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5364 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5365 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5366 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5367 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5368 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5369 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5370 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5371 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5372 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5373 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5374 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5375 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5376 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5377 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5378 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5379 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5380 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5381 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5382 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5383 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5384 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5385 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5386 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5387 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5388 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5389 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5390 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5391 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5392 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5393 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5394 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5395 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5396 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5397 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5398 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5399 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5400 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5401 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5402 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5403 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5404 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5405 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5406 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5407 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5408 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5409 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5410 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5411 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5412 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5413 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5414 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5415 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5416 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5417 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5418 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5419 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5420 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5421 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5422 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5423 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5424 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5425 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5426 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5427 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5428 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5429 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5430 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5431 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5432 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 5433 Transmission Mount: Specifications Transmission Insulator and Retainer-toCrossmember ...................................................................................................................................... ..................................... 81-108 Nm (60-80 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 5434 Transmission Mount: Service and Repair Special Tools REMOVAL 1. Raise and support the vehicle. 2. Remove the nuts. 3. Secure the (A) High lift Transmission Jack with the (B) E4OD Transmission Jack Adapter to the (C) transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 5435 4. Raise the transmission jack until the (A) retainer studs are separated from the (B) transmission support crossmember. 5. Remove the (A) bolts and the (B) retainer. INSTALLATION 1. Install the (A) retainer and the (B) bolts. 2. Lower the transmission jack while aligning the (A) retainer studs with the holes in the (B) transmission support crossmember. Allow the full weight of the transmission to rest on the transmission support crossmember. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 5436 3. Install the nuts. 4. Remove the (A) High lift Transmission Jack with the (B) E40D Transmission Jack Adapter from the (C) transmission. 5. Reinstall the transmission fluid pan-to-case retaining bolts removed to install the jack adapter. 6. Remove the supports and lower the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor .............................................................................................................................................. 8-10 Nm (75-85 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5440 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5441 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5442 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5443 Transmission Position Switch/Sensor: Service and Repair Special Tools REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1. Remove the bolts. 2. Remove the sensor. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5444 1. Install the digital transmission range (TR) sensor. 1. Install the sensor. 2. Loosely install the bolts. 2. Install the Digital Transmission Range (TR) Sensor Alignment Tool. NOTE: Make sure that the manual control lever is in the neutral position. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5445 5. Reconnect the connector. 6. Reconnect the battery ground cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor Transmission Speed Sensor: Locations Output Shaft Speed Sensor Transmission View The Output Shaft Speed Sensor is located under the vehicle, on left side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor > Page 5450 Transmission Speed Sensor: Locations Turbine Speed Sensor The Turbine Shaft Speed Sensor is located under the vehicle, on right side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5451 Output Shaft Speed Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 98-9-20 > May > 98 > A/T - E4OD 4-1 Downshift During Forced 4-2 Downshift Valve Body: Customer Interest A/T - E4OD 4-1 Downshift During Forced 4-2 Downshift Article No. 98-9-20 05/11/98 TRANSMISSION - E4OD - DOWNSHIFT DURING A FORCED 4-2 DOWNSHIFT BETWEEN 88-105 KM/H (55-65 MPH) - VEHICLES BUILT THROUGH 12/22/97 LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE Some vehicles may experience a 4-1 downshift when performing a forced 4-2 downshift (kickdown) between 88-105 km/h (55-65 mph) causing the engine rpm to increase higher than expected. This may be caused by internal leakage of fluid between the hydraulic circuits in the transmission case worm trail between the separator plate gasket and transmission case. ACTION Perform normal diagnostics as outlined in the appropriate Workshop Manual. If the concern is still present, replace the separator plate and gaskets. Refer to the Application Chart below and the appropriate Workshop Manual for replacement procedures. PART NUMBER PART NAME F8UZ-7A008-CA Separator Plate F81Z-7A008-EA Separator Plate F81Z-7C155-AA Gasket F81Z-7D100-AB Gasket OTHER APPLICABLE ARTICLES: 98-9-21 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 98O92OA Replace Separator Plate 2.1 Hrs. And Gasket DEALER CODING CONDITION BASIC PART NO. CODE 7A008, 7D100 42 OASIS CODES: 502000, 504000, 590000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage Valve Body: All Technical Service Bulletins A/T - Main Controls/Separator Plate/Gaskets Usage Article No. 98-16-8 08/17/98 TRANSMISSION - E4OD/4R100 - 1989-99 - MAIN CONTROLS, SEPARATOR PLATES AND SEPARATOR PLATE GASKETS USAGE CHART LIGHT TRUCK: 1989-96 BRONCO, F-150 1989-97 F SUPER DUTY, F-250 HD 1989-98 ECONOLINE, F-250 LD, F-35O 1997-98 EXPEDITION, F-150 1998 NAVIGATOR 1999 SUPER DUTY F SERIES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 5465 This TSB article is being republished in its entirety to revise Figure 1. ISSUE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 5466 The Chart has been developed to assist in showing the complexity and compatibility of main controls, separator plates, and plate gaskets used for E4OD/4R100 transmissions. ACTION Refer to the Usage Chart for information showing the compatibility of main controls, separator plates, and plate gaskets. This TSB should not be used in place of the Parts Catalog. NOTE TO VERIFY CORRECT GASKET USAGE, REFER TO FIGURE 1 TO IDENTIFY THE SEPARATOR PLATE I.D. NOTCHES. THEN REFER TO THE CHART TO SEE WHICH GASKETS ARE COMPATIBLE WITH THE MAIN CONTROLS AND SEPARATOR PLATES BEING USED. CAUTION MIXING COMPONENTS OTHER THAN THOSE LISTED MAY CAUSE SHIFT CONCERNS AND/OR DAMAGE TO THE TRANSMISSION. REFER TO THE PARTS CATALOG FOR PROPER USAGE BY MODEL AND YEAR. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-9-21 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000, 590000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-9-20 > May > 98 > A/T - E4OD 4-1 Downshift During Forced 4-2 Downshift Valve Body: All Technical Service Bulletins A/T - E4OD 4-1 Downshift During Forced 4-2 Downshift Article No. 98-9-20 05/11/98 TRANSMISSION - E4OD - DOWNSHIFT DURING A FORCED 4-2 DOWNSHIFT BETWEEN 88-105 KM/H (55-65 MPH) - VEHICLES BUILT THROUGH 12/22/97 LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE Some vehicles may experience a 4-1 downshift when performing a forced 4-2 downshift (kickdown) between 88-105 km/h (55-65 mph) causing the engine rpm to increase higher than expected. This may be caused by internal leakage of fluid between the hydraulic circuits in the transmission case worm trail between the separator plate gasket and transmission case. ACTION Perform normal diagnostics as outlined in the appropriate Workshop Manual. If the concern is still present, replace the separator plate and gaskets. Refer to the Application Chart below and the appropriate Workshop Manual for replacement procedures. PART NUMBER PART NAME F8UZ-7A008-CA Separator Plate F81Z-7A008-EA Separator Plate F81Z-7C155-AA Gasket F81Z-7D100-AB Gasket OTHER APPLICABLE ARTICLES: 98-9-21 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 98O92OA Replace Separator Plate 2.1 Hrs. And Gasket DEALER CODING CONDITION BASIC PART NO. CODE 7A008, 7D100 42 OASIS CODES: 502000, 504000, 590000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness Wiring Harness: All Technical Service Bulletins Recall 08V051000: Incorrect Speed Control Jumper Harness MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1994-2003 Ford/E-250 1994-2003 Ford/E-350 1994-2003 Ford/E150 1992-1993 Ford/E250 1992-1993 Ford/E350 1992-1993 Ford/Econoline 1992-2003 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-1997 Ford/Taurus SHO 1993-1995 Lincoln/Town Car 1992-1995 Mercury/Grand Marquis 1992-1998 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: February 01, 2008 NHTSA CAMPAIGN ID NUMBER: 08V051000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control: Cruise Control POTENTIAL NUMBER OF UNITS AFFECTED: 225000 SUMMARY: Ford is recalling 225,000 M?Y 1992-2003 Econoline, M/Y 1993-1995 Taurus SHO, M/Y 1992-1998 Crown Victoria, M/Y 1993 Bronco, F-Series, M/Y 1995-1997 F-Series Super Duty Stripped Chassis, M/Y 1992-1998 Mercury Grand Marquis, and M/Y 1992-1995 Lincoln Town Car vehicles. The affected vehicles were previously repaired using a wiring harness that is not compatible with the vehicle circuit polarity. CONSEQUENCE: As a result, the fuse is located in the output circuit rather than in the intended input power feed circuit, and may not offer the intended protection in the event of an electrical short to ground. REMEDY: Dealers will install a new wiring harness, or replace the mating electrical component. The recall is expected to begin during February 2008. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 08S01. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness > Page 5476 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness > Page 5482 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5483 Valve Body: Service and Repair REMOVAL NOTE: If the transmission has been disassembled to replace worn or damaged parts, and the valves in the main control valve body stick repeatedly from foreign material, the torque converter must be removed and cleaned by using a mechanically agitated cleaner, such as the Torque Converter/Oil Cooler Cleaner. 1. Disconnect the battery ground cable. WARNING: ON VEHICLES EQUIPPED WITH AN AUXILIARY BATTERY, BOTH THE NEGATIVE AND POSITIVE BATTERY CABLES MUST BE DISCONNECTED. WARNING: ON VEHICLES EQUIPPED WITH A 7.3L ENGINE, BOTH THE PRIMARY AND SECONDARY BATTERIES MUST BE DISCONNECTED. 2. Remove the transmission fluid level indicator. 3. Raise and support the vehicle. 4. On vehicles equipped with a 7.3L engine, loosen the (A) bolts and remove the (B) heat shield. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5484 5. Disconnect the connector. CAUTION: Check the electrical connectors for terminal condition, corrosion and contamination. Repair or replace as required. 6. Disconnect the connector. 7. With a suitable drain pan properly positioned, drain, then remove the transmission fluid pan and remove the gasket. 1. Loosen, but do not remove, the bolts. 2. Remove the 15 front and side fluid pan-to-case bolts. 3. Lower the front of the fluid pan and allow the fluid to drain. 4. With the fluid pan properly supported, remove the (A) bolts and the (B) fluid pan and gasket. NOTE: Do not discard the gasket unless damaged, This is a reusable gasket. 8. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5485 NOTE: After removal, discard the filter and seal assembly. 9. If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore. CAUTION: Be careful not to scratch or damage the aluminum bore. The new seal may leak. 10. Remove the (A) bolts, the (B) nuts and the (C) accumulator body. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5486 11. If the valve body separator plate is not being repaired: 1. Remove the bolt. 2. Install bolt into any case threaded bolt hole on the opposite end of the separator plate. CAUTION: Prevent the front of the valve body separator plate from sagging and displacing the check balls. 12. Remove the (B) bolts, the (C) nuts and the (D) main control valve body. NOTE: Do not remove the (A) lower-to-upper main control valve body assembly retaining bolts. Keep the main control valve bodies attached as an assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5487 13. Remove the solenoid body assembly. 1. Remove the bolts. 2. Remove the nut. 3. Remove the solenoid body assembly. 14. Remove the solenoid screen assembly by rotating and pulling it. 15. If replacing the valve body separator plate, remove the (A) bolts and the (B) separating plate reinforcing plate. CAUTION: The steel Electronic Pressure Control(EPC) check ball is spring-loaded under the valve body separator plate. 16. Lower the valve body separator plate and the gaskets carefully, to retain the rubber check balls and the steel EPC check ball and spring assembly. INSTALLATION CAUTION: using the incorrect gasket, can cause damage to the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5488 1. Assemble the new gaskets to the valve body separator plate as follows: - main control to case gasket (A) - valve body separator plate (B) - main control-to-separating plate gasket (C) NOTE: If the valve body separator plate was not removed, proceed to Step 6. NOTE: Apply a light film of petroleum jelly to the valve body separator plate prior to assembling the gaskets. 2. Position the (A) rubber check balls and the (B) steel EPC check ball on the valve body separator plate. NOTE: Apply a small amount of petroleum jelly to each check ball prior to positioning them on the valve body separator plate. 3. Install the EPC check ball spring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5489 NOTE: Apply petroleum jelly to the EPC check ball spring prior to installing it into the case. 4. Position the valve body separator plate and the gaskets to the case carefully, to retain the check balls. 5. Install the separator plate reinforcing plate. 1. Install the separator plate reinforcing plate. 2. Install the retaining bolts. NOTE: The word UP stamped on the separator plate reinforcing plate must be visible when installed, 6. Install the solenoid screen assembly by pushing it in and rotating it to lock. 7. Install the solenoid body assembly. 1. Install the solenoid body assembly. 2. Install the nut. 3. Install the bolts and nut finger-tight. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5490 NOTE: Prior to installing the solenoid body assembly, coat the case connector bore with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19331-A (Motorcraft WA-10)or equivalent meeting Ford specification ESE-M1C171-A. 8. Install the (A) main control valve body, aligning the (B) manual shift valve with the (C)inner manual valve detent lever. Install the (D) nuts and the (E) bolts finger-tight. 9. If previously installed, remove, then reinstall, the bolt into the separator plate reinforcing plate. 1. Remove the bolt. 2. Install the bolt. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5491 10. Install the (A) accumulator body with the (B) nuts and the (C) bolts finger-tight. 11. Tighten all the accumulator body, the upper and the lower control body and the solenoid body nuts and bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5492 12. Press the fluid filter and seal assembly into the pump bore until seated. NOTE: Prior to installation, lightly lubricate the seal with clean MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. 13. Position the (A) gasket onto the cleaned fluid pan. Make sure the (B) magnet is positioned over the dimple in the fluid pan. NOTE: Apply a light coat of petroleum jelly to hold the gasket to the fluid pan. The fluid pan gasket is reusable if not damaged. 14. Install the (A) pan with the gasket. Alternately tighten the (B) bolts. 15. Connect the connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5493 16. Connect the connector. 17. Install the (A) heat shield and the (B) bolts. 18. Remove the supports and lower the vehicle. 19. Connect the battery ground cable. 20. Fill the transmission to the specified level with MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Specifications > Dana Carrier Bearings: Specifications Dana Differential Bearing Cap Bolts ................................................................................................................................................. 95-122 Nm (70-90 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Specifications > Dana > Page 5500 Carrier Bearings: Specifications Ford 8.8 Inch Ring Gear Differential Bearing Cap .......................................................................................................................................................... 95-115 Nm (70-85 ft. lbs.) 9.75 Inch Ring Gear Differential Bearing Cap ......................................................................................................................................................... 95-115 Nm (70-85 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Pinion Shaft > Component Information > Specifications > Dana Carrier Pinion Shaft: Specifications Dana DANA AXLE Pinion Shaft Nut ................................................................................................................................... .............................. 298-379 Nm (220-280 ft. lbs.) Differential Pinion Shaft Lock Bolt ........................................................................................................................................... 20-34 Nm (15-25 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Pinion Shaft > Component Information > Specifications > Dana > Page 5505 Carrier Pinion Shaft: Specifications Ford Differential Pinion Shaft Lock Bolt .................................................................................................................................... 20-40 Nm (15-30 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Specifications Carrier Side Gears: Specifications 9.75-INCH RING GEAR Differential Side Gear .......................................................................................................................................................... 108-339 Nm (80-250 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Dana Differential Case: Specifications Dana Differential Case Bolts ......................................................................................................................... .......................................... 89-94 Nm (66-69 ft. lbs.) Grade 9/180 Differential Case Bolts ........................................................................................................................................ 122-136 Nm (90-100 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Dana > Page 5513 Differential Case: Specifications Ford 8.8-Inch Ring Gear Differential Case Maximum Runout .................................................................................................................................................. 0.076 mm (0.003 inch) 9.75 Inch Gear Differential Case Maximum Runout .............................................................................................................................................. 0.076 mm (0.003 inch) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation Differential Case: Service and Repair Removal and Installation Dana Special Tools Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5516 Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5517 Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5518 Special Tools Special Tools REMOVAL 1. Raise and support the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5519 2. Remove the axle housing cover and drain the lubricant from the rear axle. - Clean the gasket material from the axle housing cover and the rear axle housing. 3. Perform the following steps before disassembly. - Wipe the lubricant from the internal parts and visually inspect the parts for wear or damage. - Rotate the gears to check for any roughness, indicating damaged bearings or gears. - Check the teeth of the ring gear and pinion for signs of scoring, abnormal wear or nicks/chips. NOTE: An inspection can find the cause of the concern and determine the resolution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5520 4. Using the Dial Indicator/Magnetic Base or Dial Indicator with Bracketry with the Clutch Housing Alignment Adapter for the indicator tip, check the backlash of the ring gear and pinion. Backlash tolerance is 0.13-0.20 mm (0.005-0.008 inch) and cannot vary more than 0.05 mm (0.002 inch) between points checked. Backlash variation of more than 0.05 mm (0.002 inch) indicates incorrect runout. - High backlash is corrected by moving the ring gear toward the pinion. - Low backlash is corrected by moving the ring gear away from the pinion. - These corrections are made by changing the differential bearing selective shim thickness. NOTE: Check the ring gear and pinion backlash at three equally spaced points. 5. Remove the axle shafts. 6. Index mark the driveshaft to the rear axle companion flange. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5521 NOTE: To maintain driveline balance, mark the driveshaft components so they can be reinstalled in their original positions. 7. Remove the driveshaft-to-rear axle companion flange bolts. 8. Disconnect the driveshaft from the rear axle companion flange. Support the driveshaft to the frame using mechanics wire. 9. Remove the differential bearing retaining caps. NOTE: Mating letters are stamped on the differential bearing retaining caps and the rear axle differential carrier. The letters are in vertical and horizontal positions. Note the positions of the letters before removal. Matching the letters is important at the time of assembly. NOTE: To ease removal of the differential case, loosen the differential bearing retaining cap bolts, then pry the differential case, bearing cups and shims out until they are loose in the differential bearing retaining cups. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5522 10. Install the Differential Housing Spreader and the Dial Indicator/Magnetic Base on the axle housing. - Do not spread the rear axle housing more than 0.38 mm (0.015 inch). 11. Remove the differential case. - After the differential case is removed, remove the Differential Housing Spreader. NOTE: Large pry bars will be needed to pry the differential case from the rear axle differential carrier. Use caution to avoid damage to the ring gear. 12. Remove the differential bearing cups and the differential bearing shims. - The axle has selective shims installed outboard of each differential bearing cup. Remove both shims, indicating the side it was removed. - Inspect the shims for nicks, bending or grooved conditions. Replace as necessary. - Inspect the differential bearing cups for deep scores, galling or spalling. Replace as necessary. NOTE: Mark or tag the differential bearing cups, indicating from which side they were removed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5523 13. Using a suitable rear axle companion flange holding too], remove the drive pinion shaft nut. NOTE: Index mark the rear axle companion flange to the pinion shaft. 14. Using the 2-Jaw Puller, remove the rear axle companion flange. 15. Remove the drive pinion. - Using a soft faced hammer and the Pinion Shaft Thread Protector, tap the drive pinion out of the pinion bearing cup and remove through the rear of the axle housing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5524 16. Using the Seal Remover and Impact Slide Hammer, remove and discard the pinion seal. 17. Remove the oil slinger and pinion bearing. 18. Remove the outer pinion bearing cup. - For Dana 60/70 axles, use the Driver Handle and the Pinion Bearing Cup Remover. - For Dana 80 axles, use the Outer Pinion Bearing Cup Remover. CAUTION: Do not nick the bore of the rear axle differential carrier. 19. Using the Driver Handle and the Pinion Bearing Cup Remover, remove the inner pinion bearing cup and the drive pinion shims. NOTE: If the drive pinion shims are bent or nicked, replace as necessary. If the drive pinion shims are to be replaced, measure the shim(s) and replace with the same thickness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5525 20. Using the Pinion and Carrier Bearing Puller, remove the inner pinion bearing and the selective shim from the drive pinion. 21. Using the Pinion and Carrier Bearing Puller, remove the inner pinion bearing. NOTE: The oil slinger is part of the drive pinion bearing adjustment shims and must be kept intact for assembly. 22. Perform the following after disassembling the axle: - Thoroughly clean all parts. - Inspect all parts for damage or wear. - Clean the inside of the differential case before assembling. - When a scored or chipped ring gear and pinion is replaced, the rear axle housing should be cleaned thoroughly. INSTALLATION NOTE: Before assembling the rear axle assembly, refer to Differential Case and Pinion Set Up. 1. Place the inner and outer bearing cup and shims into the rear axle differential carrier bore. 2. Place the appropriate Pinion Bearing Cup Replacer on the inner pinion bearing cup and the outer pinion bearing cup. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5526 3. Install the Threaded Drawbar into the replacer tools and tighten. - If a 0.381 mm (0.0015 inch) feeler gauge can be inserted between a bearing cup and the bottom of its bore at any point around the bearing cup, the bearing cup must be reseated. 4. Install the drive pinion to correct depth. 1. Place a new inner pinion bearing over Aligning Adapter and insert it into the rear axle differential carrier bore. - The inner pinion bearing should rest on the Gauge Disc. The screw must thread into the Gauge Block. 2. Tighten to preload. - The 3/8-inch square drive in the handle is to be used for obtaining the proper pinion bearing preload. 3. Place the outer pinion bearing (new or used if in good condition) into the outer pinion bearing cup and assemble the Handle onto the Screw and hand-tighten. 4. Center the Gauge Tube into the rear axle differential carrier. 5. Install the bearing caps and tighten. NOTE: Use the Truck Pinion Depth Gauge-Dana only to perform the following measurement. NOTE: If any of the gauge surfaces become nicked, the high spots must be removed with a medium India oilstone to make sure there are no erroneous readings. 5. Using a feeler gauge tool or shims, select the thickest feeler shim that will enter between the Gauge Tube and the Gauge Block. Insert the feeler gauge directly along the Gauge Block so a correct reading can be made. NOTE: Make sure the shims or feeler gauges are free of dirt, to prevent an incorrect reading. NOTE: The feeler gauge fit between the Gauge Tube and the Gauge Block should have a slight drag-type feeling. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5527 6. After the correct feeler gauge feel is obtained, check the reading. This is the thickness of pinion shims required providing that, upon inspection of the service pinion gear, there are no markings. NOTE: If the service pinion gear is marked with a plus (+) reading, this amount must be subtracted from the thickness dimension obtained between the gauge block and gauge tube. NOTE: If the service pinion gear is marked with a minus (-) reading, this amount must be added to the thickness dimension obtained between the gauge block and gauge tube. NOTE: In addition, you must use the same new inner pinion bearing used in the previous steps. 7. Remove the inner pinion bearing cup and install the correct thickness of pinion shims in the rear axle differential carrier bore. CAUTION: The drive pinion preload spacer and pinion shim assembly sequence must be followed. If the sequence is not followed, unit failure can result. If pinion shims are damaged, replace them with new ones. Shims are available in the thicknesses shown in the chart. NOTE: If the oil slinger is used, replace it with a new one upon assembly and measure it as part of the shim stack. 8. Reinstall the inner pinion bearing cup. Install the oil slinger, if so equipped, between the pinion gear head and inner pinion bearing cone. 9. Press on the pinion bearing with the Axle Bearing/Seal Plate and one of the following: - The Pinion Bearing Cone Replacer for Model 70. - The Axle Bearing Seal Replacer for Model 60. - For Model 80 rear axles, use a suitable plate which contacts the bearing. 10. Assemble the pinion shims onto the pinion and install the drive pinion into the rear axle housing. Assemble the outer pinion bearing onto the drive pinion. NOTE: The thickness of the old shims may be used as a starting point for the pinion bearing preload shims. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5528 11. Install the pinion nut. - For Models 60 and 70, assemble the rear axle universal joint flange, washer and new pinion nut on the pinion stem. - For Model 80, install a new pinion nut. 12. Rotate the pinion, using an inch-pound torque wrench. To increase the preload, remove pinion shims from the outer shim pack. To decrease the preload, add shims. 13. Assemble the differential bearing cups to the differential bearings. Install the differential into the rear axle differential carrier, using the Differential Housing Spreader and the Dial Indicator/Magnetic Base. Do not spread the rear axle housing more than 0.38 mm (0.015 inch). NOTE: Before installing the differential into the rear axle housing, refer to Ring Gear and Pinion Backlash. NOTE: Use care to avoid nicking the teeth of the ring gear and the anti-lock speed sensor ring during assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5529 14. Use a rawhide hammer to seat the differential into the pocket of the rear axle differential carrier. - Remove the spreader from the rear axle differential carrier. 15. Install the differential bearing retaining caps, aligning the letters stamped on the bearing retaining caps with those on the rear axle differential carrier. Tighten the bolts of the rear axle bearing retaining caps to specification. NOTE: Mating letters are stamped on the rear axle bearing retaining caps and the rear axle differential carrier. Matching letters is important at the time of assembly. Letters are in vertical and horizontal positions. 16. Check the differential ring gear and pinion backlash at three equally spaced points, with a suitable dial indicator. - Backlash tolerance is 0.13-0.203 mm (0.005-0.008 inch) and cannot vary more than 0.05 mm (0.002 inch) between points checked. - High backlash is corrected by moving ring gear away from the pinion. - These corrections are made by switching differential bearing shims from one side of the differential case to the other. 17. To confirm total preload, recheck the torque to rotate with an inch-pound wrench. The reading should be higher than the initial reading (taken without the differential case installed) by the amount shown for the axle ratios given, if new bearings have been installed as recommended. If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5530 18. If the pinion bearing preload is within specification and the pinion position is changed, change the drive pinion bearing adjustment shim by the same amount. The direction pointing toward the rear axle universal joint flange indicates that by removing shims the distance from the centerline of the tubes to the pinion back face is increased, giving a plus (+) reading. The differential pinion bearing preload shim pack does not affect the pinion depth setting. However, if the pinion position is changed, the pinion preload will change and may require adjustment to bring the torque-to-rotation within specification. Arrows on the ring gear illustrate the method to increase or decrease backlash and differential bearing preload. 19. With the drive pinion at the correct preload as determined earlier in this procedure, remove the pinion nut and the drive pinion nut locking washer. 20. Coat the pinion seal with grease and install the pinion seal. - Use the Pinion Seal Replacer for Models 60 and 70. - Use the Pinion Oil Seal Replacer for Model 80. - After installation, make sure the garter spring did not pop out. If the garter spring pops out, remove and replace the pinion seal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5531 21. Coat the inside of the rear axle universal joint flange with a small amount of rear axle lubricant WSP-M2C197-A or equivalent and install the rear axle universal joint flange on the drive pinion shaft. For Model 80, use the Companion Flange Replacer. 22. Install the washer and nut. NOTE: Whenever the rear axle universal joint flange is removed, the pinion washer and pinion nut must be replaced. 23. Install the axle shafts. NOTE: For semi-float rear axles, remove the differential pinion shaft lock bolt and the differential pinion shaft. 24. Install the axle housing cover. - Apply Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A to the surface of the axle housing cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5532 CAUTION: Clean both flat surfaces (rear axle housing and axle housing cover) with a suitable solvent to remove all traces of oil film. NOTE: This axle housing cover requires the use of silicone rubber sealer material, such as Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A, rather than a gasket. NOTE: Axle housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. 25. Assemble two axle housing cover bolts into the axle housing cover at 8 o'clock and 2 o'clock positions. - Use these two holes to guide the axle housing cover into position on the rear axle differential carrier. 26. Install the remaining axle housing cover bolts.Tighten the bolts alternately and evenly. - Allow 1-hour cure time before filling the rear axle differential carrier with the proper amount of specified lubricant, Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5533 27. Install the driveshaft to the rear axle companion flange. NOTE: Align the index marks made during removal. 28. Fill the rear axle housing with the specified amount of lubricant: - For Models 60 (except with the 4:10 ratio) and 70, use Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. - For Models 60 (with a 4:10 ratio) and 80, use High Performance Synthetic 76-W 140 Rear Axle Lubricant F1TZ-19680-B or equivalent meeting Ford specification WSL-M2C192-A. NOTE: Check the rear axle tag for the synthetic lubrication requirement. If required, use High Performance Synthetic 75-W140 Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. NOTE: If the vehicle will be towing a trailer frequently, particularly in a hot or hilly area, it is recommended to use synthetic lubricant in the axle. 8.8-Inch Ring Gear Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5534 Special Tools REMOVAL 1. Remove the axle housing cover and drain the rear axle. 2. Remove the axle shafts. 3. Wipe the lubricant from the internal working parts and visually inspect the parts for wear or damage. 4. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. 5. Position Dial Indicator with Bracketry and inspect ring gear backlash and ring gear back face runout. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5535 NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear back face runout. 6. Loosen the differential case. 1. Remove the four bearing cap bolts. 2. Remove the two bearing caps. CAUTION: Mark the position of the bearing caps, as arrows may not be visible. The bearing caps must be installed in their identical locations and positions. 7. Use the pry bar and the wood block to remove the differential case from the rear axle housing. WARNING: BE CAREFUL NOT TO ALLOW THE DIFFERENTIAL CASE TO FALL. CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage. 8. Remove the 10 ring gear bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5536 9. Insert a punch in the bolt holes and drive off the ring gear and, if necessary, the anti-lock speed sensor ring. CAUTION: Care should be taken not to damage the ring bolt hole threads. NOTE: The anti-lock speed sensor ring cannot be reused once removed. 10. Install the differential case. - Position the differential case assembly, including the bearing clips and shims, in the rear axle housing. Install the differential bearing caps and the differential bearing cap bolts. 11. Position the Dial Indicator with Bracketry. 1. Rotate the differential case to ensure the differential bearings are properly seated. 2. Position the Dial Indicator with Bracketry. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5537 12. Measure the differential case runout without the ring gear. 1. Rotate the differential case. 2. Check and note the differential case runout. NOTE: If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings. 13. Remove the differential case from the rear axle housing and remove the differential bearings using the 2-Jaw Puller for Differential Case Bearings and the Step Plate Adapter. 14. Use Differential Side Bearing Replacer to install the new differential bearings on the differential case. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5538 15. Install the differential case. Position the differential case assembly, including the bearing caps, bolts and shims in the rear axle housing. Tighten bearing caps to specifications. 16. Measure the differential case runout without the ring gear, and check the case runout again with the new differential bearings. - If the runout is now within the specification shown, use the new differential bearings for assembly. - If the runout is still excessive, the differential case is damaged and must be replaced. INSTALLATION 1. Press a new anti-lock speed sensor ring, if removed, and the ring gear on the differential case. - Align the notch on the differential case flange with the notch on the anti-lock speed sensor ring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5539 2. Install the ring gear bolts, - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts. 3. With pinion depth set and pinion installed, place the differential case in the rear axle housing. 4. Install a shim on the left side. 5. Install the left bearing cap and loosely install the bearing cap bolts. CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5540 6. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand. 7. Install the right side bearing cap and tighten the left side and right side bolts to specification. 8. Rotate the differential case to make sure it rotates freely. 9. Use the Dial Indicator with Bracketry to measure the ring gear backlash. - If the backlash is within specification, go to Step 14. - If a zero backlash condition occurs, go to Step 10. - If the backlash is not within specification, go to Step 11. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5541 10. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Check the backlash. Repeat Step 9. 11. To increase or decrease the backlash, remove the bearing caps and install a thicker shim or a thinner shim as shown. - If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount. 12. Rotate the differential several times to make sure the differential bearings are properly seated. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5542 13. Use the Dial Indicator with Bracketry to recheck the backlash. - If the backlash is within specification, go to Step 14. If the backlash is not within specification, repeat Step 9. 14. Remove the bearing caps and bolts. - To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration. - Use the Shim Driver to ensure that the differential bearing shims are fully seated and the assembly turns freely. 15. Install the bearing caps and bearing cap bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5543 16. Use the Dial Indicator with Bracketry to recheck the backlash. 17. Install the axle shafts. 18. Install the driveshaft. 19. Install the axle housing cover and refill the rear axle with specified lubricant. 9.75-Inch Ring Gear Special Tools Special Tools REMOVAL 1. Remove the axle housing cover and drain the axle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5544 2. Remove the axle shafts. 3. Mark the driveshaft flange and the driveshaft rear axle companion flange for correct alignment during installation. 4. Wipe the lubricant from the internal working parts, and visually inspect the parts for wear or damage. 5. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. 6. Position the Dial Indicator with Bracketry, and inspect ring gear backlash and ring gear back face runout. NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear back face runout. 7. Loosen the differential case. 1. Remove the bearing cap bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5545 2. Remove the bearing caps. CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions. 8. Use the pry bar and the wood block to remove the differential case from the rear axle housing. WARNING: BE CAREFUL NOT TO ALLOW THE DIFFERENTIAL CASE TO FALL. CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage. 9. Remove the ring gear bolts. 10. Insert a punch in the bolt holes. Drive off the ring gear and, if necessary, the anti-lock speed sensor ring. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5546 11. Install the differential case 1. Position the differential case assembly, including bearing clips and shims, in the carrier. 2. Install the differential bearing caps. 3. Install the differential bearing cap bolts. 12. Position the Dial Indicator with Bracketry. 1. Rotate the differential case to make sure the differential bearings are properly seated. 2. Position the Dial Indicator with Bracketry. 13. Measure the differential case runout without the ring gear. 1. Rotate the differential case. 2. Check and note the differential case runout. NOTE: If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5547 14. Remove the differential case from the rear axle housing, and remove the differential bearings using the 2-Jaw Puller for Differential Case Bearings and the Step Plate. 15. Use the Differential Side Bearing Replacer to install the new differential bearings on the differential case. 16. Measure the differential case runout without the ring gear. - Check the case runout again with the new differential bearings. If the runout is now within the specification shown, use the new differential bearings for assembly. If the runout is still excessive, the differential case is damaged and must be replaced. INSTALLATION 1. Press the ring gear and, if removed, a new anti-lock speed sensor on the differential case Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5548 2. Install the ring gear bolts. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. 3. With pinion depth set and the pinion installed, place the differential case in the rear axle housing. 4. Install a shim on the left side. 5. Install the left bearing cap, and loosely install the bearing cap bolts. CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5549 6. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand. 7. Install the right side bearing cap, and tighten the bolts. 8. Rotate the differential case to make sure it rotates freely. 9. Use the Dial Indicator with Bracketry to measure ring gear backlash. - If the backlash is within specification, go to Step 15. The specification shown in the illustration is the total allowable range. - If a zero backlash condition occurs, go to Step 10. - If the backlash is not within specification, go to Step 11. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5550 10. If a zero backlash condition occurs, add a 0.50 mm (0.020 inch) shim to the RH side and subtract 0.50 mm (0.020 inch) from the LH side to allow backlash indication. Check backlash. Repeat Step 9. 11. To increase or decrease backlash, remove the bearing caps, and install a thicker shim and a thinner shim as shown. - If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount. 12. Install the bearing caps and bearing cap bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5551 13. Rotate the differential several times to make sure the differential bearings are properly seated. 14. Use the Dial Indicator with Bracketry to recheck the backlash. - If backlash is within specification, go to Step 15. If not, repeat Step 9. - The specification shown in the illustration is the total allowable range. 15. Remove the bearing caps and bolts. - To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration. - Use a shim driver to ensure the differential bearing shims are fully seated and the assembly turns freely. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5552 16. Install the bearing caps and bearing cap bolts. 17. Use the Dial Indicator with Bracketry to verify the backlash. - The specification shown in the illustration is the total allowable range. 18. Install the axle shafts. 19. Install the axle housing cover, and refill the rear axle with specified lubricant. 20. Install the driveshaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5553 Differential Case: Service and Repair Disassembly and Assembly Dana Special Tools DISASSEMBLY 1. Remove the differential bearings with the Pinion and Carrier Bearing Puller. - Wire the differential bearing shims, differential bearing cup, differential bearing and outboard selective spacer together. Note from which side they were removed (ring gear side or opposite side). NOTE: Differential bearing shims are available in thicknesses of 0.762, 0.787, 0.813, 0.838, 0.864, 0.889 and 0.914 mm (0.030, 0.031, 0.032, 0.033, 0.034, 0.035 and 0.036 inch). NOTE: If differential bearing shims are damaged, replace with new ones. NOTE: Replace the differential bearings whenever they are removed from the rear axle differential carrier. 2. Place the differential case in a vise. NOTE: Place a few shop towels over the vise to prevent the teeth of the ring gear from being nicked. 3. Remove the bolts on the ring gear. Leave four bolts loosely assembled, 90 degrees apart. CAUTION: Use care not to damage the anti-lock speed sensor ring when removing the ring gear. If the anti-lock speed sensor ring is removed, it must be replaced with a new one. NOTE: Whenever removing the ring gear bolts, always replace them with new bolts upon assembly. Use Grade 9 bolts for service replacement Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5554 for all Dana rear axles. 4. Tap each bolt head alternately with a rawhide or plastic hammer to loosen the ring gear. Remove the bolts and the ring gear. 5. If required, remove the anti-lock speed sensor ring with a soft-faced hammer. Discard the anti-lock speed sensor ring. 6. Place the differential case in a vise. For full-floating rear axles, use a small drift to drive out the differential pinion shaft lock pin that secures the differential pinion shaft. For semi-float rear axles, remove the differential pinion shaft lock bolt. 7. Remove the differential pinion shaft. - On full-floating rear axles; use a drift. - On semi-floating axles, remove by hand. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5555 8. To remove the differential side gears and the differential pinion gears, rotate the differential side gears. The differential pinion gears will turn to the opening of the differential case. 9. Remove the differential pinion gears and the differential pinion thrust washers behind the differential pinion gears. 10. Lift out the differential side gears and the differential side gear thrust washers. ASSEMBLY 1. Place the differential case in a vise. Apply Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B to new differential side gear thrust washers and to rear hubs and thrust face of the new differential side gears. 2. Apply grease to the new differential pinion thrust washers and the new differential pinion gears. 3. Assemble both differential side gears and differential side gear thrust washers. Hold in place with hand, then assemble the differential pinion gears and differential side gear thrust washers to hold the differential side gears in place. NOTE: An easy way to assemble the differential side gears and differential pinion gears is to have all parts lubricated with rear axle lubricant WSP-M2C197-A or equivalent before assembly. 4. If necessary, use a drift to line up the holes with those of the differential case. NOTE: Rotate the differential side gears until the holes of the differential side gear thrust washers and the differential pinion gears line up with the holes of the differential case. If the differential pinion gears cannot be rotated by hand, install one of the axle shafts into the spline of the differential side gear and use a pipe wrench to turn the axle shaft. 5. Assemble the differential pinion shaft and drive on the differential pinion shaft to remove the drift. Align the lock pin hole of the differential pinion shaft with the lock pin hole of the differential case 6. Install a new differential pinion shaft lock pin after assembling the axle shafts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5556 NOTE: The semi-float axle shaft riding bearing design uses a differential pinion shaft lock pin that is assembled using a 12-point socket wrench. Use a new differential pinion shaft lock pin and assemble finger-tight only. This procedure is necessary to prevent the differential side gears and the differential pinion gears from rotating in the differential case and dropping out when servicing the rear axle differential carrier. 7. For full-floating axle shafts, assemble the differential pinion shaft lock pin. Peen the metal of the differential case over the differential pinion shaft lock pin in two places, 180 degrees apart, to lock in place. Note the location of the slot in the differential pinion shaft lock pin and peen 90 degrees away. 8. Align the tab in the anti-lock speed sensor ring with the slot in the differential case. Start the two ring gear bolts through the differential case flange into the ring gear to make sure the differential case and the ring gear bolt hole align. NOTE: The tab on the anti-lock speed sensor ring must be aligned with the slot in the differential case. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5557 9. Press the anti-lock speed sensor ring on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring. Apply Thread lock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G315-A5 (TYPE II) to the new ring gear bolts. 10. Draw up the Grade 9 ring gear bolts alternately and evenly. 11. Install the differential bearings. NOTE: Refer to Differential Case and Pinion Setup. 8.8-Inch Ring Gear Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5558 Special Tools DISASSEMBLY 1. Remove the differential case, 2. Remove the 10 ring gear bolts. 3. Insert a punch in the bolt holes and drive the ring gear off. CAUTION: Care should be taken not to damage the bolt hole threads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5559 4. Remove the speed sensor ring if required. NOTE: The speed sensor ring cannot be reused once removed. 5. If required, use 2-Jaw Puller for Differential Case Bearings and the Step Plate Adapter to remove the differential bearing. 6. Remove the differential pinion shaft lock bolt. 7. Remove the differential pinion shaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5560 8. Rotate and remove the differential pinion gear and differential pinion thrust washer. 9. Remove the differential side gear and the differential pinion thrust washer. ASSEMBLY 1. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B meeting Ford specification WSL-M2C192-A to lubricate the differential side gear thrust washer and the differential side gear journals. Position the differential side gear thrust washer on the differential side gear. 2. Position the differential side gear. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5561 3. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2Cl92-A to lubricate the differential side gear thrust washer and the differential pinion gear and assemble. 4. Engage the differential pinion gear opposite the differential side gear. 5. Rotate the differential pinion gear to align with the differential pinion shaft bore. 6. Insert the differential pinion shaft. - Align the hole in the differential pinion shaft with the hole in the differential case. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5562 7. Install a new differential pinion shaft lock bolt and tighten finger-tight. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Thread lock and Sealer EOAZ-19554-AA or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. 8. Use Differential Side Bearing Replacer to install the new differential bearings on the differential case. 9. Press the new anti-lock speed sensor ring and the ring gear on the differential case. 10. Install the ring gear bolts. - Apply Stud and Bearing Mount EOAZ-19554-B or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts. 11. Install the differential case. 9.75-Inch Ring Gear Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5563 Special Tools DISASSEMBLY 1. Remove the differential case. 2. Remove the ring gear bolts. 3. Insert a punch in the bolt holes and drive the ring gear off. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5564 4. Remove the anti-lock speed sensor ring. NOTE: The anti-lock speed sensor ring cannot be reused once removed. 5. If required, remove the differential bearings with the 2-Jaw Puller for Differential Case Bearings and the Step Plate Adapter. 6. Remove the differential pinion shaft lock bolt and the differential pinion shaft. 7. Rotate and remove the differential pinion gears and differential pinion thrust washers. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5565 8. Remove the differential side gears and the differential side gear thrust washers. ASSEMBLY 1. Position the differential side gear thrust washers on the differential side gears. - Use Premium Synthetic Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A to lubricate the differential side gear thrust washers and the differential side gear journals. 2. Position the differential side gears. 3. Assemble the differential pinion thrust washers and the differential pinion gears. - Lubricate with Premium Synthetic Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5566 4. Engage the differential pinion gears opposite the differential side gears. 5. Install the differential bearings, using the Differential Side Bearing Replacer. 6. Rotate the differential pinion gears to align the differential pinion shaft bore. 7. Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight. 8. Press the new anti-lock speed sensor ring and the ring gear on the differential case. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5567 9. Install the ring gear bolts and tighten. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. 10. Replace the differential bearings, if removed. 11. Install the differential case. Model 60 Special Tools Special Tools DISASSEMBLY NOTE: When axle lubricant has been drained for rear axle repair (limited slip only), refill the rear axle with the specified quantity of Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A, and add 0.148 L (5 ounces) of Ford Friction Modifier C8AZ-19B546-A or equivalent friction modifier meeting Ford specification EST-M2C118-A. NOTE: The 4.10 ratio Model 60 axle in E-350 vans and club wagons is filled with 75W-140 synthetic lubricant meeting Ford specification WSL-M2C192-A. The limited-slip 4.10 ratio in this axle also uses Ford Friction Modifier C8AZ- 1913546-A or equivalent meeting Ford specification EST-M2C118-A. NOTE: It is not necessary to remove the differential bearings to overhaul the limited slip differential; however, the ring gear may have to be removed first. NOTE: For some ratios, the differential pinion shafts can be removed without removing the ring gear. In most cases, the unit can be disassembled without removing the ring gear, which saves the cost of new ring gear screws. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5568 ' 1. For Model 60-1U full-float axles, use a small drift to remove the differential pinion shaft lock pin retaining the differential pinion shaft. For Model 60-1U semi-float rear axles, a differential pinion shaft lock bolt is used to secure the slip-fit differential pinion shaft. NOTE: An axle shaft placed in a vise, with the splines extending not more than three inches above the jaws of the vise, makes an excellent holding fixture after the differential case has been removed from the rear axle housing. 2. Remove the differential pinion shaft. - For the Model 60-1U full-float axle, use a hammer and drift to remove. 3. Position the Step Plate into the bottom of the differential side gear. Apply grease to the centering hole of the step plate. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5569 4. Install the Forcing Nut and Screw into the differential case. Guide the Forcing Screw into the step plate. 5. Tighten the forcing screw to move the differential side gears away from the differential pinion gears and relieve the normal loaded condition. CAUTION: Do not overtighten the forcing screw. Overtightening the forcing screw can damage the rear axle disc and plate kit. 6. Using a piece of 0.762 mm (0.030 inch) thick shim or gauge stock, push out the differential pinion thrust washers located behind the differential pinion gears. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5570 7. Momentarily loosen the forcing screw. NOTE: This step is very important to relieve the pressure of the rear axle disc and plate kit. 8. Retighten the forcing screw until a very slight movement of the differential pinion gears is seen. NOTE: When attempting to rotate the differential side gear, some tightening or loosening of the forcing screw will probably be required to permit gear movement. 9. Insert the Driver Handle into the bore of the differential pinion shaft and rotate the differential case until the differential pinion gears can be removed through the large openings in the differential case. 10. Using one hand to retain the top differential side gear and rear axle disc and plate kit in the differential case, remove the forcing screw. 11. Continue to hold the differential side gear and the rear axle disc and plate kit, and remove the gear rotating tool. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5571 12. Remove the top differential side gear and the rear axle disc and plate kit. Keep the stack of clutch plates and clutch discs in exact order. 13. Turn the differential case so the flange or ring gear side is up. Ease the Step Plate, differential side gear and rear axle disc and plate kit out of the differential case. 14. Remove the retainer clips from both rear axle disc and plate kits to allow separation of the clutch discs and clutch plates for cleaning and inspection. 15. Inspect the following components. - The clutch plates and clutch discs for cracks, excessive wear, and distortion. If one or more of the clutch plates or clutch discs needs replacing, replace the entire stack of clutch plates on both sides. - The surfaces of the differential pinion shaft and the differential case for excessive wear or pitting. - The teeth of the differential side gears and the differential pinion gears. ASSEMBLY NOTE: Always replace entire rear axle disc and plate kits, even if only one component requires it. NOTE: Before installing the rear axle disc and plate kits, differential side gears and differential pinion thrust washers, assemble them in exactly the same order as removed. 1. Prelubricate the thrust faces of the differential side gears and assemble the clutch plates and clutch discs to the splines of the differential side gears, prelubricating each part of both stacks with 75W-140 Synthetic Lubricant or equivalent meeting Ford specification WSL-M2C192-A or with Ford Friction Modifier C8AZ-19B546-A or equivalent friction modifier lubricant meeting Ford specification EST-M2C118-A. 2. Assemble the retainer clips to the ears of the clutch plates. Make sure both clips are completely assembled or seated onto the ears of the clutch plates. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5572 3. Assemble the rear axle disc and plate kit and differential side gear into the differential case. Make sure the rear axle disc and plate kit stays assembled to the splines of the differential side gear, and the retainer clip is completely seated into the pocket of the differential case. NOTE: To prevent the rear axle disc and plate kit from falling out of the differential case, hold in place by hand while repositioning the differential case on a bench. 4. Reposition the differential case on the bench. Assemble Step Plate into the bottom side gear bore. - Apply a small amount of Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B into the centering hole of the step plate. 5. Assemble the other differential clutch pack and differential side gear. Install Forcing Nut and Screw to the differential side gear. - Hold the differential side gear in position by hand. - Insert the forcing screw down through the top of the differential case, and thread the forcing nut on the screw. The tip of the forcing screw must contact the step plate. NOTE: Make sure the differential clutch pack stays assembled to the splines of the differential side gear, and the retainer clips are completely seated into the pockets of the differential case. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5573 6. With the Forcing Nut and Screw assembled to the differential case, position the differential case onto the axle shaft (as a holding fixture) by aligning the splines of the differential side gear with those of the axle shaft. 7. Position both differential pinion gears opposite one another through the openings in the differential case. Align the holes of the differential pinion gears with each other. Hold the differential pinion gears in place by hand. 8. Tighten the forcing screw so the differential side gears move away from the differential pinion gears and relieve the loaded condition. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5574 9. While holding the differential pinion gears in place, insert the Driver Handle into the hole of the differential pinion shaft in the differential case. Pull on the handle, rotating the differential case and allowing the differential pinion gears to rotate and enter into the differential case. 10. Adjust the forcing screw by very slightly loosening or tightening it until the required load is applied to allow the differential side gears and differential pinion gears to rotate. 11. Rotate the differential case until the holes of both differential pinion gears are aligned with those of the differential case. 12. Apply torque to the forcing screw for clearance to assemble the differential pinion thrust washers. CAUTION: Do not overtighten the forcing screw. Overtightening the forcing screw can damage the rear axle disc and plate kit. 13. Assemble the differential pinion thrust washers into the differential case. - Use a very small screwdriver to push the washers into place. NOTE: During assembly, make sure the holes of the differential pinion thrust washers and differential pinion gears are lined up exactly with those of the differential case. 14. Remove the forcing screw, forcing nut, handle and step plate. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5575 15. Install the differential pinion shaft in the differential case. Install the differential pinion shaft lock pin. For Model 60 semi-float axles, tighten the differential pinion shaft lock bolt finger-tight. After axle shaft installation, tighten the differential pinion shaft lock bolt to specification. 16. Install the ring gear to the differential case, if required. Model 70 (Dual Rear Wheels) DISASSEMBLY NOTE: When the axle lubricant has been drained for rear axle repair (limited slip only), refill the rear axle with the specified quantity of Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A and add 0.163 L (5.5 ounces) of Ford Friction Modifier C8AZ-1913546-A or equivalent friction modifier meeting Ford specification EST-M2C118-A. 1. Mark the differential case. 1. Mark the flange (ring gear) half and button (cover) half of the differential case for reassembly in the same positions. 2. Mark the differential pinion shafts and their corresponding ramps for reassembly in the same positions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5576 2. Clamp the differential in a soft-jawed vise. Insert an axle shaft into the differential to act as a holding tool. Loosen the differential case bolts. Do not remove. 3. Place the differential on the bench with the flange half of the differential case down. Remove the differential case retaining bolts and button half of the differential case. 4. Remove the differential side gear, side gear ring, and rear axle disc and plate kit. Keep these parts with the button half of the differential case to reinstall in the original positions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5577 5. Remove the side gear ring, clutch discs, and clutch plates from the flange half of the differential case, and keep them in their original order by placing them on the rear axle universal joint flange as shown in the illustration. 6. Inspect the following components: - The clutch plates and clutch discs for cracks, excessive wear, and distortion. If one or more of the clutch plates or clutch discs needs replaced, replace the entire rear axle disc and plate kit. Inspect all other parts and replace any worn or damaged part. - The surfaces of the differential pinion shafts and the ramp surfaces on the differential case for excessive wear or pitting. - The teeth of the differential side gears and differential pinion gears. Inspect the differential side gear races that bear on the differential side gear rings. ASSEMBLY 1. Place the differential side gear ring from the flange half of the differential case on the rear axle universal joint flange approximately 4 inches above the bench. Coat the clutch plates with axle lubricant, Premium Rear Axle Lubricant XY-8OW90-QL or equivalent meeting Ford specification WSP-M2C197-A and Ford Friction Modifier C8AZ-1913546-A or equivalent meeting Ford specification EST-M2C118-A. CAUTION: The clutch packs (without radial grooves) must be soaked for 20 minutes in Ford Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A before assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5578 2. Assemble the clutch pack in the flange half of the differential case. NOTE: After assembly, make sure that the side gear splines engage the clutch pack splines and the differential side gear is fully seated. 3. Assemble the clutch pack plates for the button half of the differential case. Align the clutch pressure plate lugs, and install into the differential case. NOTE: There may be circumstances of continuing chatter/bumping in turns despite replacement of parts and lubricant, particularly in vehicles operating at close to GVW rating. Typical situations are emergency vehicles and fifth wheel trailers. In these cases, it is permissible to reassemble the rear axle disc and plate kit with the clutch disc adjacent to the differential side gear ring, resulting in two clutch plates together. This results in three friction surfaces instead of the normal five, lowering the torque to rotate the wheel by 40 percent. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5579 4. Assemble the pinions and gears inside the differential case. - Place the differential pinion shaft and differential pinion gears with the markings on the button half of the differential case. - Install the other differential pinion shaft and differential pinion gears on the flange half of the differential case. Align the markings. 5. Assemble the differential case. 1. Place the button half of the differential case over the assembly. Align differential case marks. 2. Install the differential case bolts and turn each one on a few threads. NOTE: The bolts must be clean and dry. 3. With the axle shafts in position, tighten the differential case bolts evenly and alternately to specification. If bolt heads have "180" or seven radial lines (Grade 9) stamped on them, tighten the differential case bolts to the appropriate specification. 6. If the assembly has been properly assembled, each differential pinion shaft should be tight on its ramp. If there is clearance between the differential pinion shaft and the ramp, it must be not more than 0.254 mm (0.010 inch) and equal at all four ends of the differential pinion shafts. 8.8-Inch Ring Gear Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5580 Special Tools DISASSEMBLY 1. Remove the differential case. 2. Remove the 10 ring gear bolts. 3. Insert a punch in the bolt holes and drive the ring gear off. CAUTION: Care should be taken not to damage the bolt hole threads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5581 4. Remove the speed sensor ring, if required. NOTE: The anti-lock speed sensor ring cannot be reused once removed. 5. Use the 2-Jaw Puller for Differential Case Bearings and the Step Plate Adapter to remove the differential bearing. - Repeat for the other side. 6. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft. 7. Remove the differential clutch spring. WARNING: DUE TO THE SPRING TENSION, CARE MUST BE USED WHEN REMOVING THE DIFFERENTIAL CLUTCH SPRING Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5582 8. Remove the differential gears. 1. Remove the two differential pinion gears. 2. Remove the two differential side gears. 3. Remove the two differential pinion thrust washers. 9. Remove the differential clutch packs and differential side gears and tag them "right" and "left" with the shim. - Clean and inspect the remaining parts of the differential case for wear or damage and replace parts as necessary. CAUTION: Keep the differential clutch packs in order. Do not mix them. They must be reassembled in the same sequence. 10. Clean and inspect the differential clutch packs for wear and replace parts as necessary. CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5583 ASSEMBLY 1. Prelubricate each steel clutch plate and soak all friction plates with additive Ford Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes. CAUTION: 118 ml(4 oz) of the specified Ford Friction Modifier must be used in the axle. 2. Assemble the differential clutch packs (without the shims) on the respective differential side gears CAUTION: Do not mix the differential clutch packs or shims from one side with the other. 3. Place the base portion of Traction-Lok Clutch Gauge in a vise. Install the differential clutch pack and differential side gear (without the shim) on the gauge. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5584 CAUTION: Make sure the proper mandrel is used with a Traction-Lok Clutch Gauge. 4. Position the Traction-Lok Clutch Gauge hand-tight on top of the differential clutch pack. 5. Install Top Traction-Lok Clutch Gauge over the disc and differential clutch pack. 6. Install the nut of the gauge over the top and base stud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5585 7. Use the Feeler Gauge and select the thickest blade that will enter between the too] and the differential clutch pack. The reading will be the thickness of the new clutch shim. 8. Remove Traction-Lok Clutch Gauge from the clutch pack and side gear assembly. 9. Install shims on the clutch pack and side gear assembly. 10. Install the differential side gear in the differential case. 11. Install the differential pinion gears with differential pinion thrust washers in the differential case. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5586 12. Install the differential clutch spring, using a soft-faced hammer. 13. Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight. 14. Use the Differential Side Bearing Replacer to install the differential bearing on the differential case. Repeat for the other side. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5587 15. Install the anti-lock speed sensor ring by aligning the tab on the anti-lock speed sensor ring with the slot on the differential case. - Start two of the ring gear bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes properly. 16. Press the new anti-lock speed sensor ring and the ring gear on the differential case. 17. Install the ring gear bolts. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. 18. Install the differential case. 9.75-Inch Ring Gear Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5588 Special Tools Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5589 DISASSEMBLY 1. Remove the differential case. 2. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft. - If required, remove the ring gear and anti-lock speed sensor ring. NOTE: The differential bearings need not be removed to overhaul the Ford limited slip differential. If bearing removal is required, use the 2-Jaw Puller for Differential Case Bearings. NOTE: The anti-lock speed sensor ring cannot be reused once removed. 3. Install the Traction-Lok Torque Tool in a suitable vise. 4. Install the differential case on the tool. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5590 5. Install the Step Plate Adapter in the bottom side gear bore. Apply a small amount of grease to the centering hole of the Step Plate Adapter. 6. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with the Step Plate Adapter. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5591 7. Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gear away from the differential pinion gears. The dowel bar is used to keep the nut from turning when the forcing screw is tightened. 8. Insert Limited Slip Differential Rotating Tool in the pinion shaft bore, and turn the differential case to "walk" the differential pinion gears and differential pinion thrust washers out to the differential case windows. WARNING: KEEP FINGERS/HANDS AWAY FROM PINION GEARS WHEN ROTATING THE DIFFERENTIAL CASE WITH THE DIFFERENTIAL ROTATING TOOL. NOTE: Differential pinion thrust washers cannot be removed independently of the differential pinion gears and so must be removed simultaneously with the differential pinion gears. 9. Remove the differential pinion gears and differential pinion thrust washers. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5592 10. Remove the differential side gears and differential clutch packs, and tag them RIGHT and LEFT with the shim. 11. Separate the differential clutch discs and clutch plates for cleaning and inspection. CAUTION: When separating the clutch plates and clutch discs, note the sequence in which they are disassembled. They must be reassembled in the same sequence. CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only. ASSEMBLY 1. Prelubricate each steel clutch plate and soak all friction plates with 118 ml (4 ounces) Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5593 2. Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears. NOTE: Do not mix the differential clutch packs or shims from one side with the other. NOTE: The Belleville spring is a dished plate. 3. Clamp the bolt head of the Traction-Lok Clutch Gauge in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge. NOTE: Use the Traction-Lok Clutch Gauge Mandrel for the procedure. 4. Position the Traction-Lok Clutch Gauge on top of the differential clutch pack . Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5594 5. Install the Traction-Lok Clutch Gauge over the disc and differential clutch pack. 6. Install the nut of the gauge over the top and base stud. 7. Use the Feeler Gauge and select the thickest blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim. Select the correct shim size, and remove the Traction-Lok Clutch Gauge. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5595 8. Place the shim and Belleville spring on the differential clutch pack. - The dished or concave side of the Belleville spring must face up and against the thrust face of the differential case. 9. Insert the differential clutch packs with shims and Belleville springs and differential side gears into the differential case. - Hold the upper clutch pack and side gear assembly in place to prevent it from falling out of the differential case. 10. Assemble the forcing screw, nut and Step Plate Adapter to the differential case . 1. Position the Step Plate Adapter in the bottom side gear bore. 2. Position the nut in the top side gear bore and hold it in place. 3. Install the hex-head screw and tighten it two turns after it contacts the bottom step plate. NOTE: Apply a small amount of grease to the step plate bore. NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5596 11. Position the differential pinion gears and differential pinion thrust washers in the window of the differential case so they mesh with the differential side gear teeth. NOTE: Prelubricate both sides of the differential pinion thrust washers with Premium Synthetic Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. NOTE: Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore. 12. Insert the rotating handle into the pinion shaft bore, and turn the differential case. This will cause the differential pinion gears to engage the differential side gears and "walk" into the differential case. Rotate the differential case until the pinion mating shaft holes are lined up exactly with the holes in the differential pinion gears. WARNING: KEEP FINGERS/HANDS AWAY FROM PINION GEARS WHEN ROTATING THE DIFFERENTIAL CASE WITH THE DIFFERENTIAL ROTATING TOOL. NOTE: It will probably be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate. 13. Loosen the forcing screw, and remove the step plate and nut from the side gear bores. Install a new differential pinion shaft in the differential case. - Install the differential pinion shaft lock bolt finger-tight. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5597 14. Install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the retaining bolts. 15. Replace the differential bearings, if removed. 16. Install the differential case. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5598 Differential Case: Service and Repair Set Up - Dana Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5599 Special Tools DIFFERENTIAL CASE RUNOUT CHECK 1. Install the appropriate Dummy Differential Bearing from the Master Bearing Set. 2. Remove all nicks, burrs, dirt, etc., from the rear hubs, to allow the bearings to rotate freely. 3. Install the outboard differential selective spacers into the rear axle differential carrier. Assemble the differential case into the rear axle differential carrier (less pinion). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5600 4. Mount the Dial Indicator/Magnetic Base or Dial Indicator with Bracketry as shown. Locate the tip of the indicator with the Clutch Housing Alignment Adapter on a flat surface of one of the ring gear screw spot faces. NOTE: The Dial Indicator should have a minimum travel capability of 5.08 mm (0.200 inch). NOTE: The rear axles use a combination of hard inboard spacers and selective outboard shims. The old outboard selective shims can be used as a starting point. If additional shimming is required other than what can be obtained with the hardened inboard spacers, a new outboard selective shim must be used. 5. Force the differential case as far as possible toward the indicator. With force still applied, set indicator at 0. NOTE: Repeat Steps 5-7 until you have obtained the same reading each time. Record the reading of the indicator. This is the total amount of differential bearing shims required (less preload) and will be calculated later during assembly. 6. Force the differential as far as it will go in the opposite direction. 7. After making sure the readings are correct, remove the indicator and the differential from the rear axle housing. Do not remove the master bearings from the differential case at this time. 8. This reading is the total differential case end play, which will be needed for assembly of the differential into the housing. PINION RING GEAR VARIATION NUMBER NOTE: If the rear axle drive pinion shaft oil slinger is bent or mutilated, it must be replaced. NOTE: Ring gear and pinions are supplied in matched sets only. Matching numbers are etched on both the ring gear and pinion for verification. If a new ring gear and pinion is being used, verify the numbers of each ring gear and pinion before proceeding with assembly. The end of the pinion with Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5601 the etched figures shown is known as the "button" end. NOTE: Use the gear contact pattern method to make sure the final pinion position is valid. 1. Shim the drive pinion as follows: - On the button end of each pinion, there is etched a plus (+), a minus (-) or a zero (0) number, which indicates the best running position for each particular ring gear. This dimension is controlled by the shimming behind the inner pinion bearing cup (the back face). - For example, if a pinion is etched m+8 (+3), this pinion requires 0.08 mm (0.003 inch) less drive pinion shims than a pinion etched " 0 " This means by removing drive pinion shims, the mounting distance of the pinion is increased, which is what an m+8 (+3) indicates. Or if a pinion is etched m-8 (-3), add 0.08 mm (0.003 inch) more shims than would be required if the pinion were etched "0". By adding 0.08 mm (0.003 inch) pinion shims, the mounting distance of the pinion is decreased, which is what an m-8 (-3) indicates. 2. Measure the distance between the centerline of the ring gear to the back face of the drive pinion. - The distance from the centerline of the ring gear to the back face of the pinion: - 127 mm (5.000 inches) for Model 60-1U - 136.5 mm (5.375 inches) for Model 70 - 147.6 mm (5.812 inches) for Model 80 3. If the old ring gear and pinion is to be reused, measure the old pinion shims and build a new pack of shims to this same dimension. If a baffle is used in the rear axle assembly, it is considered part of the shim pack. To change the pinion adjustment, pinion shims are available in thicknesses of 0.08, 0.13 and 0.25 mm (0.003, 0.005 and 0.010 inch). - Measure each shim separately with a micrometer and add together to get the total shim pack thickness from the original buildup. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5602 4. If a new ring gear and pinion is being used, notice the (+) or (-) etching on both the old and new pinion and adjust the thickness of the new shim pack to compensate for the difference of these two figures. For example, if the old pinion reads m+5 (+2) and the new is m-5 (-2), add 0.10 mm (0.004 inch) pinion shims to the original shim pack. RING GEAR AND PINION GEAR BACKLASH 1. Using the Differential Housing Spreader, place the differential case into the rear axle housing. Differential master bearings should still be assembled to the differential case. Install the outboard spacers in the same side as removed from, when making overall measurement. 2. Set up the Dial Indicator/Magnetic Base or Dial Indicator with Bracketry. Locate the dial indicator tip, which is the Clutch Housing Alignment Adapter, on a flat surface of one of the ring gear bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5603 3. Force the differential case assembly (ring gear) away from the drive pinion. With force still applied to the differential case, set the indicator at zero. 4. Force the differential case assembly (ring gear) into mesh with the drive pinion to obtain an indicator reading. NOTE: Repeat the following step until the same reading is obtained each time. This reading is the necessary amount of pinion shims required between the differential case and the differential bearings on the differential ring gear and pinion side. 5. Remove the Dial Indicator and the differential case from the rear axle differential carrier. 6. Remove the master bearings from the differential case . 7. As determined from the measurement obtained under Differential Case End Play Check, place the required amount of shims on the ring gear side. For example, if the reading was 1.14 mm (0.045 inch), place at least one hardened shim as supplied in the service kit on the differential case hub and make up the difference with the outboard selective shim. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5604 8. Using the Differential Bearing Cone Replacer, install the bearing cone on the ring gear side of the differential case. 9. To determine the correct amount of shims to be placed on the hub of the drive pinion side of the differential case, subtract the reading obtained in this procedure from the total differential case end play. Total case end play was determined under Differential Case End Play Check. When this amount is determined, add 0.36 mm (0.015 inch) to the amount for Models 60 and 70 or 0.25 mm (0.010 inch) for Model 80. This is the required amount of shims to be placed on the hub of the drive pinion side of the differential case. For example, the total differential case end play on a Model 60 was 2.30 mm (0.091 inch) The reading earlier was 1.14 mm (0.045 inch), and when subtracted from 2.30 mm (0.091 inch) equals 1.16 mm (0.046 inch). Add 0.36 mm (0.015 inch), to give 1.52 mm (0.061 inch) of pinion shims to be placed on the side of the drive pinion of the differential case. 10. Install required amount of shims on the drive pinion side of the differential case. 11. Install the bearing cone on the hub of the drive pinion side of the differential case. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal and Installation > Page 5605 1. Place the Step Plate on the ring gear side bearing to protect the bearing during the installation of the drive pinion side bearing. 2. Drive the bearing onto the drive pinion side hub, using the Differential Bearing Cone Replacer. 12. Install the Differential Housing Spreader and the Dial Indicator/Magnetic Base or Dial Indicator with Bracketry to the rear axle differential carrier. Remove the indicator. CAUTION: Do not spread the rear axle differential carrier over 0.38 mm (0.015 inch). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Dana Differential Cover: Specifications Dana Cover to Housing Bolts ........................................................................................................................ .......................................... 68-88 Nm (50-65 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Dana > Page 5610 Differential Cover: Specifications Ford 8.8 Inch Ring Gear Axle Housing Cover Bolts ................................................................................................................................................. 38-52 Nm (28-38 ft. lbs.) 9.75 Inch Ring Gear Axle Housing Cover ........................................................................................................................................................... 38-52 Nm (28-38 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear Differential Cover: Service and Repair 8.8 Inch Ring Gear REMOVAL 1. Raise and support the vehicle. 2. Remove the axle housing cover. 1. Remove the 10 axle housing cover bolts and drain the lubricant from the rear axle housing. 2. Remove the axle housing cover. INSTALLATION 1. Clean the gasket mating surface of the rear axle and the axle housing cover. CAUTION: Make sure the machined surfaces on both the rear axle housing and the axle housing cover are clean and free of oil before installing the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination. 2. Apply a new continuous bead of sealant to the axle housing cover. - Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A. 3. Install the axle housing cover. 1. Install the axle housing cover. 2. Install the 10 axle housing cover bolts. NOTE: The axle 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 properly cured. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5613 4. Fill the rear axle with 2.4 liters (5.5 pints) of Thermally Stable Rear Axle Lubricant XY-8OW90-QL or equivalent meeting Ford specification WSP-M2C197-A and install the filler plug. CAUTION: For Traction-Lok axles, first fill the rear axle with 118 ml (4 oz) of specified Ford Friction Modifier. NOTE: Service refill capacities are determined by filling the rear axle to the level shown. 5. Lower the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5614 Differential Cover: Service and Repair 9.75 Inch Ring Gear REMOVAL 1. Raise and support the vehicle. 2. Remove the axle housing cover. 1. Remove the 12 axle housing cover bolts, and drain the lubricant from the rear axle housing. 2. Remove the axle housing, cover. INSTALLATION 1. Clean the gasket mating surface of the rear axle and the axle housing cover. CAUTION: Make sure the machined surfaces on both the rear axle housing and the axle housing cover are clean and free of oil before applying the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination. 2. Apply a new, continuous bead of sealant to the axle housing cover. - Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A. 3. Install the axle housing cover and tighten the axle housing cover bolts. NOTE: The axle housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied, If possible, allow 1 hour before filling with lubricant to ensure the silicone sealant has properly cured. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5615 4. Fill the rear axle with Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A, and install the filler plug. CAUTION: For Traction-Lok axles, first fill the rear axle with 118 ml (4 ounces) of specified Ford Additive Friction Modifier. NOTE: Service refill capacities are determined by filling the rear axle with the specified lubricant to the specified level below the bottom of the filler hole. 5. Lower the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Specifications > Mechanical Specifications Differential Axle Housing: Mechanical Specifications 8.8-Inch Ring Gear Rear Axle Housing Vent .......................................................................................................................................................... 11-24 Nm (8-18 ft. lbs.) 9.75-Inch Ring Gear Rear Axle Housing Vent .......................................................................................................................................................... 11-24 Nm (8-18 ft. lbs.) Differential Axle Housing Rear Axle Pinion Angle to Horizontal: 5.4 L ..................................................................................................................................................... ................................ 5.81 @ Empty Angle Degree 6.8, 7.3 L .............................................................. ................................................................................................................ 6.10 @ Empty Angle Degree Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Specifications > Mechanical Specifications > Page 5620 Differential Axle Housing: Capacity Specifications Axle Model: 60-1U ................................................................................................................................................... .............................................. 3.0 L (6.3 US pints) 70-2U .................................................................... ............................................................................................................................. 3.1 L (6.6 US pints) 70-HD .................................................................................................................................................. ............................................... 3.5 L (7.4 US pints) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Specifications > Mechanical Specifications > Page 5621 Differential Axle Housing: Fluid Type Specifications NOTE: Use Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A for Model 60 or Model 70. For Model 80, use High Performance Synthetic 75-W140 Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Use Ford Friction Modifier or equivalent meeting Ford specification ST-M2C118-A for complete refill of Dana limited slip rear axles. Add 0.2 liter (8 oz) for complete refill. The 4.10 ratio Model 60 is equipped with WSL-M2Cl92-A synthetic lubricant as factory fill. If any Econoline vehicle will be towing a trailer frequently, particularly in a hot or hilly area, it is recommended that the axle be filled with 75W-140 synthetic lubricant or equivalent meeting Ford specification WSL-M2C192-A. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Specifications > Page 5622 Differential Axle Housing: Testing and Inspection NOTE: If the vent cannot be cleared, it must be replaced. A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leak occurs, check the vent. Make sure the vent hose is not kinked. Remove the hose from the vent nipple and clear the hose of any foreign material. While the hose is removed, pass a length of mechanics wire or a small diameter Allen wrench in and out of the vent to clean it. Connect the hose when done. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana Differential Axle Housing: Service and Repair Dana REMOVAL 1. Disconnect the battery ground cable(s). 2. Raise and support the vehicle. 3. Loosen the adjusting nut at the parking brake cable equalizer, until the right side (upper) and left side (lower) cable anchors are free from the equalizer retaining slots. Disconnect the cables at the equalizer. NOTE: Prior to disconnecting the rear parking brake cables, note left and right side cable routing. NOTE: To maintain proper adjustment, measure and record the distance from the top of the parking brake cable equalizer adjusting nut to the end of the stud. 4. Slide the boxed end of a 13mm wrench over the rear parking brake cable and onto the cable conduit retainer. Depress the retainer locking tabs and pull the cable conduit toward the rear of the vehicle and out from the parking brake cable support bracket. 5. Separate the left side rear parking brake cable from the support spring at the frame rail. - Tie-wrap the cable to the axle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana > Page 5625 6. Separate the right side rear parking brake cable from the support spring. NOTE: Use care so as not to dislodge the cable support spring from the frame rail. 7. Disconnect the Anti-Lock Brake Sensor (RABS). Disconnect the RABS harness from the retainers and position it aside. 8. Disconnect the right side rear parking brake cable from the retainers at the axle. Separate the cable from the frame and pull the cable around the front of the axle. Tie-wrap the cable to the axle. 9. Remove the driveshaft. 10. Position a suitable drain pan under the axle, below the brake hose. Disconnect the brake line at the brake hose. - Plug the hose and line fittings. - Discard the brass washers. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana > Page 5626 11. Remove the brake hose-to-frame bracket retaining clip. Separate the brake hose from the bracket. 12. Remove the left and right side shock absorber lower nuts. Do not remove the retaining bolts at this time. 13. Remove the supports and lower the hoist completely. 14. Remove the shock absorber lower bolts. Disconnect the shock absorbers at the axle. 15. Raise the hoist enough to access the axle U-bolt nuts through the wheel housing. CAUTION: The tires must remain on the ground to support the axle. 16. Support the front of the rear axle housing. CAUTION: Prevent the front of the axle housing from dropping and the brake lines from twisting when loosening the axle U-bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana > Page 5627 17. Remove the axle U-bolt nuts and the axle U-bolts. 18. While watching for obstructions, raise the hoist until the vehicle is clear of the axle and tires. 19. Roll the axle, with the housing support, from under the vehicle. INSTALLATION 1. With the vehicle raised to the appropriate height to clear the axle and tires, and the front of the axle housing supported, roll the axle under the vehicle and position it for installation. 2. While watching for obstructions, lower the hoist until the spring positioning pins contact the axle housing pad. While adjusting the hoist as required, have an assistant align the spring positioning pins to the axle pads. 3. Install the axle U-bolts and snug the axle U-bolt nuts. 4. Alternately tighten the axle U-bolt nuts. 5. Adjust the hoist as required. Install the shock absorber to the brackets at the axle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana > Page 5628 6. Raise and support the vehicle. 7. Position the brake hose into the retaining bracket and install the retaining clip. 8. Connect the brake line to the brake hose. NOTE: Position a suitable drain pan under the axle, below the brake hose. 9. Remove the tie wraps retaining the rear parking brake cables to the axle. 10. Properly route the right side rear parking brake cable around the axle and through the frame. Connect the cable to the retainers at the axle and to the support spring at the frame. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana > Page 5629 11. Reconnect the RABS sensor, and the RABS harness to the retainers. 12. Properly route the left side rear parking brake cable for installation, and connect the cable to the support spring at the frame. 13. Install the right side (upper) and left side (lower) rear parking brake cables into the parking brake cable support bracket. 14. Connect the right side (upper) and the left side (lower) cable anchors to the parking brake cable equalizer and position into the retaining slots. Tighten the parking brake cable equalizer adjusting nut until the previously recorded measurement is obtained. 15. Install the driveshaft. 16. Remove the supports and lower the vehicle. 17. Reconnect the battery ground cable(s). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana > Page 5630 18. Bleed the hydraulic brake system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana > Page 5631 Differential Axle Housing: Service and Repair Ford 8.8-Inch Ring Gear REMOVAL 1. Raise and support the vehicle. 2. Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 3. Remove the four driveshaft bolts and disconnect the driveshaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana > Page 5632 4. Disconnect the parking brake cable. 1. Loosen the adjusting nut at the parking brake cable equalizer, until the right side (upper) and left side (lower) cable anchors are free from the equalizer retaining slots. Disconnect the cables at the equalizer. 2. Slide the boxed end of a 13 mm wrench over the rear parking brake cable and onto the cable conduit retainer. Depress the retainer locking tabs and pull the cable conduit toward the rear of the vehicle and out from the parking brake cable support bracket. Repeat for the opposite cable. 3. Separate the left side rear parking brake cable from the support spring at the frame rail. Tie-wrap the cable to the axle. 4. Separate the right side rear parking brake cable from the support spring. NOTE: Use care so as not to dislodge the cable support spring from the frame rail. NOTE: Prior to disconnecting the rear parking brake cables, note left and right side cable routing. Also, to maintain proper adjustment, measure and record the distance from the top of the parking brake cable equalizer adjusting nut to the end of the stud. 5. Disconnect the right side rear parking brake cable from the retainers at the axle. Separate the cable from the frame and pull the cable around the front of the axle. Tie-wrap the cable to the axle. 6. Disconnect the rear brake anti-lock sensor electrical connector. 7. Disconnect the rear axle brake hose and rear axle vent tube at the frame. 8. Remove the two lower shock absorber nuts only (one on each side). WARNING: DO NOT REMOVE THE LOWER SHOCK ABSORBER BOLTS AT THIS TIME. 9. Lower the vehicle until the tires are in contact with the floor. Support the front of the rear axle housing. 10. Remove the lower shock absorber bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana > Page 5633 11. Remove the rear axle U-bolt assembly. 1. Remove the four rear spring plate nuts. 2. Remove the two rear spring plate U-bolts. 3. Remove the rear spring plate, 4. Repeat the procedure for the other side. 12. Raise the vehicle until clear of the rear axle. INSTALLATION 1. Follow the removal procedure in reverse order. - Bleed the rear brakes. 9.75-Inch Ring Gear Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana > Page 5634 REMOVAL 1. Raise and support the vehicle. 2. Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 3. Remove the four driveshaft bolts, and disconnect the driveshaft. 4. Disconnect the parking brake cables. 1. Loosen the adjusting nut at the parking brake cable equalizer, until the right side (upper) and left side (lower) cable anchors are free from the equalizer retaining slots. Disconnect the cables at the equalizer. 2. Slide the boxed end of a 13 mm wrench over the rear parking brake cable and onto the cable conduit retainer. Press the retainer locking tabs, and pull the cable conduit toward the rear of the vehicle and out from the parking brake cable support bracket. Repeat for the opposite cable. 3. Separate the left side parking brake rear cable and conduit from the support spring at the frame rail. Tie-wrap the cable to the rear axle. Wire the driveshaft out of the way. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana > Page 5635 4. Separate the right side parking brake rear cable and conduit from the support spring. NOTE: Use care not to dislodge the cable support spring from the frame rail. NOTE: Prior to disconnecting the parking brake rear cable and conduit, note left and right side cable routing. Also, to maintain proper adjustment, measure and record the distance from the top of the parking brake cable equalizer adjusting nut to the end of the stud. 5. Disconnect the right side parking brake rear cable and conduit from the retainers at the axle. Separate the cable from the frame, and pull the cable around the front of the rear axle. Tie-wrap the cable to the rear axle. 6. Disconnect the rear brake anti-lock sensor electrical connector. 7. Disconnect the rear axle brake hose and rear axle vent tube at the frame. 8. Remove only the two lower shock absorber nuts (one on each side). WARNING: DO NOT REMOVE THE LOWER SHOCK ABSORBER BOLTS AT THIS TIME. 9. Lower the vehicle until the tires are in contact with the floor. Support the front of the rear axle housing. 10. Remove the lower shock absorber bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana > Page 5636 11. Remove the rear axle U-bolt assembly. 1. Remove the rear spring plate nuts. 2. Remove the rear spring plate U-bolts. 3. Remove the rear spring plate. 4. Repeat the procedure for the other side and remove the rear axle assembly. 12. Raise the vehicle until it is clear of the rear axle. INSTALLATION 1. Follow the removal procedure in reverse order. - Bleed the rear brakes. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Drain Plug, Differential > Component Information > Specifications > Dana Drain Plug: Specifications Dana Oil Filler Plug ....................................................................................................................................... ..................................... 27-41 Nm (20-30 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Drain Plug, Differential > Component Information > Specifications > Dana > Page 5641 Drain Plug: Specifications Ford 8.8 Inch Ring Gear Oil Filler Plug ....................................................................................................................................... ................................. 20-40 Nm (15-30 ft. lbs.) 9.75 Inch Ring Gear Oil Filler Plug ....................................................................................................................................... ................................. 20-40 Nm (15-30 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Dana 60-1U ......................................................................................................................................... ......................................................................... 6.3 pt. Dana 70 ............................................................................................................................................... ......................................................................... 6.5 pt. Dana 70HD .......................................................................................................................................... ........................................................................ 7.5 pt. Ford 8.8 inch ........................................................................................................................................ ........................................................................ 5.5 pt. Ford 9.75 inch ...................................................................................................................................... ........................................................................ 5.5 pt. Note: Fill to 1/4 to 9/16 inch below fill hole. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 5646 Fluid - Differential: Fluid Type Specifications Standard .............................................................................................................................................. .......................................... Synthetic 75W-140 GL-5 Limited Slip .......................................................................................................................................... ...................................... Synthetic 75W-140 GL-5+ Note: Part no. XY-75W140-QL Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > 8.8-Inch Ring Gear Pinion Bearing: Specifications 8.8-Inch Ring Gear Pinion Maximum Runout ..................................................................................................................... ................................................ 0.25 (0.010 T.I.R.) Pinion Bearing Preload ......................................................................................................................................................... 1.8-3.3 Nm (16-29 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > 8.8-Inch Ring Gear > Page 5651 Pinion Bearing: Specifications 9.75-Inch Ring Gear Pinion Bearing Preload Used Pinion Bearing ......................................................................................................................................................... 0.9-1.5 Nm (8-14 inch lbs.) New Pinion Bearing ......................................................................................................................................................... 1.8-33 Nm (16-29 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear Pinion Bearing: Service and Repair 8.8-Inch Ring Gear Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5654 Special Tools REMOVAL 1. Remove the differential case. 2. Mark the driveshaft flange and the driveshaft rear axle companion flange for correct alignment during installation. 3. Remove the four rear driveshaft bolts and disconnect the rear driveshaft. 4. Install an Nm (inch lbs.) torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 5. Remove the rear axle companion flange and pinion nut. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5655 6. Using a soft-faced hammer, drive the pinion assembly out of the front bearing cone and remove it through the rear of the housing. - Remove the rear axle drive pinion seal. - Remove the rear axle drive pinion shaft oil slinger. 7. Use the Bearing Pulling Attachment to remove the pinion bearing. NOTE: Remove the collapsible spacer and discard it. 8. If the pinion bearing cups are to be replaced, tap alternately (with a brass drift of suitable length) on opposite sides of the cup during removal to the prevent the cup from cocking in the casting. NOTE: Do not remove the pinion bearing cups from the carrier casting unless the cups are damaged. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5656 1. Drive the outer pinion bearing cup into the axle housing using the Pinion Bearing Cup Replacer and Driver Handle. 2. Drive the inner pinion bearing cup into the axle housing using the Pinion Bearing Cup Replacer and Driver Handle. 3. Make sure the cups are properly seated in their bores. CAUTION: Whenever the cups are replaced, the pinion bearings must also be replaced. NOTE: If a feeler gauge can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not properly seated. 4. Assemble and position the Pinion Depth Gauge. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5657 NOTE: Apply only a light oil film on the pinion bearings before assembling the tool. 5. Tighten the Driver Handle to the specification shown. 6. Rotate the Gauge Block several half-turns to ensure proper seating of the pinion bearings and position the Gauge Block. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5658 NOTE: The Gauge Block must be offset to obtain an accurate reading. 7. Install the Gauge Tube. 1. Position the Gauge Tube. 2. Install the differential side bearing caps. 3. Install the four differential side bearing cap bolts. 8. Use a drive pinion bearing adjustment shim as a gauge for shim selection. - After the proper shim thickness has been determined, remove the Gauge Tube. NOTE: Drive pinion bearing adjustment shims must be flat and clean. NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in final assembly of integral rear axle assemblies. 9. Use a press and Pinion Bearing Cone Replacer to press the pinion bearing until it is firmly seated on the pinion and pinion shim. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5659 10. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder. 11. From inside the rear axle housing, install the drive pinion assembly (drive pinion, shims, rear bearing cone and roller, and drive pinion collapsible spacer) into the rear axle carrier bore. 12. Install a new rear axle drive pinion seal. 1. Install the front pinion bearing cone and roller. 2. Install the rear axle drive pinion shaft oil slinger in the rear axle housing . 3. Install the rear axle drive pinion seal on the Pinion Seal Replacer. CAUTION: Installation without the proper tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one. 13. Place the Pinion Seal Replacer in the rear axle drive pinion seal bore, and drive the rear axle drive pinion seal into place. NOTE: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5660 ESA-M1C75-B. 14. Lubricate the rear axle companion flange splines. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 15. Align the rear axle companion flange with the drive pinion shaft. NOTE: Disregard the scribe marks if a new rear axle companion flange is being installed. 16. With the drive pinion in place in the rear axle housing, install the rear axle companion flange using the Companion Flange Replacer. 17. Position the new pinion nut. 18. Use the Companion Flange Holding tool to hold the rear axle companion flange while tightening the pinion nut. - Refer to the torque specification for new pinion bearings. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5661 CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. 19. Install the differential case in the rear axle differential carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5662 Pinion Bearing: Service and Repair 9.75-Inch Ring Gear Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5663 Special Tools Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5664 Special Tools REMOVAL 1. Remove differential case. 2. Mark the driveshaft flange and the driveshaft rear axle companion flange for correct alignment during installation. 3. Remove the four rear driveshaft bolts, and disconnect the rear driveshaft. Wire the driveshaft out of the way, 4. Install a Nm (inch lbs.) torque wrench on the pinion nut, and record the torque required to maintain rotation of the pinion through several revolutions. 5. Remove the rear axle companion flange and pinion nut. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5665 6. Remove the rear axle drive pinion shaft oil slinger. 7. Remove the rear axle drive pinion seal. 8. Install Pinion Shaft Thread Protector and, with a soft-faced hammer, drive the pinion out of the outer pinion bearing and remove the drive pinion through the rear of the housing. 9. Remove the collapsible spacer and discard it. 10. Use the Bearing Pulling Attachment to remove the pinion bearing cone and roller assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5666 11. If the pinion bearing cups are to be replaced, tap alternately (with a brass drift of suitable length) on the opposite side of the cups during removal to prevent cups from cocking in the casting. NOTE: Do not remove the pinion bearing cups from the carrier casting unless the cups are damaged. INSTALLATION 1. Drive the outer pinion bearing cup into the axle housing, using the Pinion Bearing Cup Replacer (Outer) and the Driver Handle. 2. Drive the inner pinion bearing cup into the axle housing, using the Pinion Bearing Cup Replacer (Inner) and the Driver Handle. 3. Make sure the cups are properly seated in their bores. CAUTION: Whenever the cups are replaced, the differential pinion bearings must also be replaced. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5667 NOTE: If a feeler gauge of the specification shown in the illustration can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not properly seated. 4. Assemble and position the Pinion Depth Gauge. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5668 5. Tighten the Driver Handle. 6. Rotate the Gauge Block several half-turns to ensure proper seating of the pinion bearings, and position the Gauge Block. NOTE: The Gauge Block must be offset to obtain an accurate reading. 7. Install the Gauge Tube. 1. Position the Gauge Tube. 2. Install the differential side bearing caps. 3. Install the differential side bearing cap bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5669 8. Use a drive pinion bearing adjustment shim as a gauge for shim selection. - After the proper shim thickness has been determined, remove the Gauge Tube. NOTE: Drive pinion bearing adjustment shims must be flat and clean. NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tool contact in the final assembly of integral rear axle assemblies. 9. Use a press and the Pinion Bearing Cone Replacer to press the pinion bearing until it is firmly seated on the pinion and pinion shim. 10. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder. 11. Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing. Seat the drive pinion with a plastic hammer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5670 12. Install a new rear axle drive pinion seal. 1. Install the outer pinion bearing cone and roller. 2. Install the rear axle drive pinion shaft oil slinger in the rear axle housing. 3. Install the rear axle drive pinion seal on the Pinion Seal Replacer. CAUTION: Installation without the proper tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one 13. Place the Pinion Seal Replacer in the pinion seal bore and drive the rear axle drive pinion seal into place. NOTE: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-13. 14. Lubricate the rear axle companion flange splines. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 15. Align the rear axle companion flange with the drive pinion shaft. NOTE: Disregard the scribe marks if a new rear axle companion flange is being installed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5671 16. With the drive pinion in place in the axle housing, install the rear axle companion flange using the Companion Flange Replacer. 17. Position the new pinion nut. 18. Use a suitable companion flange holding tool to hold the rear axle companion flange while tightening the pinion nut. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. 19. Install the differential case. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Testing and Inspection Pinion Flange: Testing and Inspection CAUTION: Pinion bearing preload must be reset if the pinion nut has been loosened or removed for companion flange reindexing or replacement. 1. Raise the vehicle on a twin-post hoist that supports the rear axle. 2. Remove the driveshaft. 3. Check the companion flange for damage. 4. Position the Companion Flange Runout Gauge on the companion flange. 5. Position the Clamp Plate onto the Companion Flange Runout Gauge. 6. Align the holes on the clamp plate with the holes in the companion flange and install the bolts. Snug the bolts evenly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Testing and Inspection > Page 5675 7. Position the Dial Indicator/Magnetic Base as shown. Turn the Companion Flange Runout Gauge, and locate and mark the high spot on the companion flange with yellow paint. If the flange runout exceeds 0.25 mm (0.010 inch), remove the companion flange, reindex the flange one-half turn on the pinion, and reinstall it for the flange removal and installation procedures. 8. Check the runout again. If necessary, rotate the flange until an acceptable runout is obtained. If the flange runout is still more than 0.25 mm (0.010 inch), replace the companion flange. 9. If excessive runout is still evident after replacement of the companion flange, replace the ring and pinion. Repeat the above checks until the runout is within specifications. 10. Install the driveshaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications Pinion Gear: Specifications 9.75-INCH RING GEAR Available Pinion Gear Shim ....................................................................................................................................... 0.533-0.94 mm (O.021-0.037 inch) Differential Pinion Shaft ............................................................................................................................................................ 20-40 Nm (15-30 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Dana Ring Gear: Specifications Dana Ring Gear Attaching Bolts: Grade 8 ................................................................................................................................................ ......................... 136-163 Nm (100-120 ft. lbs.) Grade 9 ...................................................................... ................................................................................................... 163-190 Nm (120-140 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Dana > Page 5683 Ring Gear: Specifications Ford 8.8 Inch Gear Maximum Back face Ring Gear Runout ............................................................................................................................................ 0.102 mm (0.004 inch) Backlash Between Ring Gear and Pinion Teeth ...................................................................................................................................... 0.203-0.381 mm (0.008-0.015 inch) Ring Gear Maximum Backlash Variation Between Teeth ..................................................................................................................... .......................................... 0.102 mm (0.004 inch) 9.75 Inch Gear Maximum Back Face Ring Gear Runout ....................................................................................................................................... 0.102 mm (0.004 inch) Backlash Between Ring ............................................................................................................................................ O.203-0.381 mm (0.008-0.015 inch) Ring Gear Maximum Backlash Variation Between Teeth .................................................................................................................................... ..................................... 0.102 mm (0.004 inch) Ring Gear Bolts ................................................................................................................................... ............................... 136-163 Nm (100-120 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Forward Hub and Ring Gear Ring Gear: Service and Repair Forward Hub and Ring Gear DISASSEMBLY 1. Remove the No. 8C forward clutch hub thrust washer. 2. Remove the forward hub retaining ring. 3. Remove the forward hub. ASSEMBLY 1. Follow the removal procedure in reverse order. - Lightly lubricate the thrust washer with petroleum jelly to hold it in place during assembly. - When installed, make sure the retaining ring is fully seated in the forward ring gear ring groove. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Forward Hub and Ring Gear > Page 5686 Ring Gear: Service and Repair Overdrive Ring Gear and Center Shaft Assembly DISASSEMBLY 1. Remove the flat retaining ring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Forward Hub and Ring Gear > Page 5687 2. Remove the overdrive one-way clutch with the inner and the outer races. 3. Remove the No. 3 overdrive overrunning clutch thrust washer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Forward Hub and Ring Gear > Page 5688 4. Remove the overdrive planet assembly. NOTE: The No. 4 overdrive planet thrust bearing may stay in the ring gear. 5. Remove the wavy retaining ring. 6. Remove the overdrive center shaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Forward Hub and Ring Gear > Page 5689 7. Inspect the No. 4 overdrive planet thrust bearing assembly. 1. Remove the No. 4 overdrive planet thrust bearing assembly. Wash the thrust bearing thoroughly in cleaning solvent. Blow dry the bearing with compressed air and lubricate with clean transmission fluid. Replace any bearing and race that show sign of wear. 2. Inspect the pinion shafts in the planet assembly. They should be checked for looseness and damage. 3. Inspect the pinion gears for damaged and free rotation. 4. Inspect the planet carrier for damage. CAUTION: Use care not to damage the thrust bearing. NOTE: The individual parts of the planet assemblies are not repairable. 8. Push out the unitized plastic cage and the inner race. 9. Inspect the rollers or sprags, springs and cage for excessive wear or damage. Remove the inner race. NOTE: Inspect the outer and inner races for scores or damaged surface areas where the rollers or sprags contact the races. ASSEMBLY Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Forward Hub and Ring Gear > Page 5690 1. Install the overdrive center shaft. 2. Install the wavy retaining ring. NOTE: The retaining ring is used to hold the center shaft in the ring gear. 3. Install the No. 4 overdrive planet thrust bearing assembly. NOTE: Make sure the bearing outer lip faces the rear face of the overdrive planet assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Forward Hub and Ring Gear > Page 5691 4. Install the overdrive planet assembly. CAUTION: The input shaft and overdrive planet assembly are repaired as mating components. NOTE: Different vehicle applications will have different planet assemblies. 5. Install the No. 3 overdrive overrunning clutch thrust washer. 6. Install the retaining ring and the unitized plastic cage. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Forward Hub and Ring Gear > Page 5692 7. Install the inner race, with the (A) undercut toward the (B) small retaining ring. NOTE: When installed, the inner race must rotate counterclockwise. 8. Install the overdrive one-way clutch. NOTE: The small retaining ring must face upward. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Forward Hub and Ring Gear > Page 5693 9. Install the flat retaining ring. 10. Install the No. 5 overdrive center shaft thrust bearing assembly. NOTE: Lightly lubricate the thrust bearing with petroleum jelly to hold it in place during assembly. NOTE: The inner bearing race lip must face upward. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Forward Hub and Ring Gear > Page 5694 11. Install the overdrive center shaft assembly. 1. Remove the (A) selective coast clutch pressure plate retainer snap ring, the (B) coast clutch pressure plate and the (C) clutch plates from the (D) coast clutch cylinder. 2. Install the (E) overdrive center shaft assembly into the (D) coast clutch cylinder. 3. Reinstall the (C) clutch plates, the (B) coast clutch pressure plate and the (A) selective coast clutch pressure plate retainer snap ring into the (D) coast clutch cylinder. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inspection Seals and Gaskets: Service and Repair Inspection Leaks at the axle drive pinion seal originate for the following reasons: Seal was not properly installed. - Poor quality seal journal surface. Any damage to the seal bore (dings, dents, gouges, or other imperfections) will distort the seal casing and allow leakage past the outer edge of the axle drive pinion seal. The axle drive pinion seal can be torn, cut, or gouged if it is not installed carefully. The spring that holds the axle drive pinion seal against the companion flange may be knocked out and allow leakage past the lip. The rubber lips can occasionally become hard (like plastic) with cracks at the oil lip contact point. The contact point on the companion flange may blacken, indicating excessive heat. Marks, nicks, gouges, or rough surface texture on the seal journal of the companion flange will also cause leaks. Axle drive pinion seal wear 1.27 mm (0.050 inch) or greater is considered excessive. The companion flange must be replaced if any of these conditions exist. Metal chips or sand trapped at the sealing lip can also cause oil leaks. This can cause a wear groove on the companion flange and heavy pinion seal wear. When a seal leak occurs, replace the seal and check the vent and the vent hose to make sure they are clean and free of debris. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inspection > Page 5699 Seals and Gaskets: Service and Repair Dana Special Tools REMOVAL 1. Raise the vehicle on a hoist or raise the rear end of the vehicle with a jack. Install safety stands under the frame rails and lower the jack or hoist far enough to allow the rear axle to drop into the rebound position for working clearance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inspection > Page 5700 2. Index mark the driveshaft to the rear axle companion flange. 3. Remove the driveshaft-to-rear axle companion flange bolts. 4. Disconnect the driveshaft from the rear axle companion flange. Support the driveshaft to the frame using mechanics wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inspection > Page 5701 5. Using a suitable companion flange holding tool to hold the rear axle universal joint flange, remove the drive pinion shaft nut. NOTE: Index mark the rear axle companion flange to the pinion shaft. 6. Using the 2-Jaw Puller, remove the rear axle universal joint flange. 7. Using the Seal Remover in combination with the Impact Slide Hammer, remove the pinion seal. 8. Clean the rear axle pinion seal seat. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inspection > Page 5702 1. Follow the removal procedure in reverse order. - Coat the pinion seal (rubber lips) with Premium Rear Axle Lubricant XY-8OW90-QL or equivalent meeting Ford specification WSP-M2C197-A. CAUTION: Installation without the proper tool can result in early seal failure. If the pinion seal becomes cocked during installation, remove and install a new one. Use care to ensure the garter spring remains in place during assembly. If the spring is dislodged, the pinion seal must be replaced. NOTE: Drive the pinion seal into the housing, using the Pinion Seal Replacer for Model 60 or 70 axle. NOTE: The rear axle universal joint flange must never be hammered on or installed with power tools. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inspection > Page 5703 Seals and Gaskets: Service and Repair Ford 8.8 Inch Ring Gear Special Tools REMOVAL 1. Remove the rear axle companion flange. 2. Pry up on the metal flange of the rear axle drive pinion seal. Install gripping pliers and strike with a hammer until the rear axle drive pinion seal is removed. INSTALLATION 1. Lubricate the new rear axle drive pinion seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. Use Pinion Seal Replacer to install the rear axle drive pinion seal. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the rear axle drive pinion seal and install a new seal. 3. Install the rear axle companion flange. 9.75 Inch Ring Gear Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inspection > Page 5704 Special Tools REMOVAL 1. Remove the rear axle companion flange. 2. Pry up on the metal flange of the pinion seal. Install gripping pliers and strike with a hammer until the pinion seal is removed. INSTALLATION 1. Lubricate the new pinion seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. Use the Pinion Seal Replacer to install the pinion seal. CAUTION: If the pinion seal becomes misaligned during installation, remove the seal and replace. 3. Install the rear axle companion flange. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Replacement Axle Bearing: Service and Repair Replacement REMOVAL 1. Remove the axle shaft bolts. - Place a drain pan under the rear hub. 2. Remove the axle shaft. 3. Inspect the following components: - The rear axle shaft gasket for damage; replace as necessary. - The axle shaft for cracks around the bolt holes. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Replacement > Page 5710 E-350 1. Follow the removal procedure in reverse order. NOTE: If the original bolts are being reused, apply a suitable thread adhesive to the bolts. NOTE: Torque specifications are the same for SRW or DRW vehicles. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Replacement > Page 5711 Axle Bearing: Service and Repair Overhaul Special Tools Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Replacement > Page 5712 Special Tools Special Tools DISASSEMBLY 1. Set the parking brake and loosen the axle shaft bolts. 2. Raise and support the vehicle. - Place safety stands under the rear axle housing. 3. Release the parking brake and back off the rear brake adjustment, if necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Replacement > Page 5713 4. Using a suitable wheel dolly, raise the wheels to the point that all the weight is removed from the wheel bearings. Remove the tire and wheel assembly. 5. Remove the axle shaft bolts. - Place a drain pan under the rear hub. 6. Remove the axle shaft. 7. On E-350 vehicles, remove the brake drum. NOTE: If so equipped, the push-on sheet metal drum retainer nuts can be discarded. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Replacement > Page 5714 8. On E-Super Duty vehicles, remove the anchor plate. 9. Remove the hub nut. NOTE: The hub nuts have right-handed threads on both spindles. Do not use power tools on the hub nuts. 10. Remove the outer bearing cone and pull the rear hub straight out and away from the rear axle. 11. Clean the spindle of the rear axle housing. 12. Remove and discard the hub seal. Carefully remove the hub seal from the rear hub with a screwdriver, avoiding damage to the hub bore. 13. Clean all the old grease and axle lubricant out of the rear hub. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Replacement > Page 5715 14. Inspect the bearing rollers for pitting, galling or erratic wear patterns. Inspect the rollers for end wear. 1. A typical new bearing roller. 2. A worn bearing roller. 15. Remove the inner and outer bearing cups. - For E-Super Duty vehicles, remove the bearing cups using the Inner Bearing Cup Remover, Outer Bearing Cup Remover and Driver Handle. - For E-350 vehicles, remove the bearing cups using a brass drift. 16. Inspect the cups for pitting, galling or excessive wear. If either the cup or bearing is worn or damaged, replace both components. 17. Inspect the rear hub. Replace the rear hub if any of the following conditions exist: - cracked material around bolt holes - depth of holes 40 mm (1.57 inches) - threaded for 25 mm (1 inch) - oversized holes ASSEMBLY Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Replacement > Page 5716 1. Install the bearing cups. - For E-350, install the new cups with the Bearing Cup Replacer or the Bearing Cup Replacer and the Threaded Drawbar. - For E-Super Duty, use the Bearing Cup Replacer and Threaded Drawbar. CAUTION: Check for proper seating of the new bearing cups by trying to insert a 0.038 mm (0.0015 inch) feeler gauge between the cups and the rear hub. The gauge should not enter beneath the cup. Check several places to make sure the cups are squarely seated. 2. Using 4 suitable bearing packer, pack each rear wheel bearing assembly with a lithium-base grease, Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 3. Place the inner rear wheel bearing in the rear hub. 4. Install a new hub seal. - For E-350 vehicles, use the Seal Replacer or Seal Replacer and Threaded Drawbar. - For E-Super Duty vehicles, install the hub seal with the Hub Seal Replacer. 5. Carefully slide the rear hub (rear hub and rotor on E-Super Duty) straight (to avoid seal damage) onto the axle housing spindle. NOTE: Wrap the threads of the spindle with electrician's tape. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Replacement > Page 5717 6. Install the outer rear wheel bearing. NOTE: Fill the cavity in the rear hub with axle lubricant before installing the outer rear wheel bearing. 7. Install the hub nut. Rotate the rear hub occasionally while tightening to set the bearings. 8. After tightening the hub nut as per the previous step, ratchet the hub nut back 90 degrees, then tighten it to the final specification. The final bearing adjustment is to have zero end play. The maximum torque to rotate the hub is shown in the illustration. NOTE: This procedure is intended to provide no side-to-side end play of the hub and wheel bearings. This can be verified using the Dial Indicator/Magnetic Base mounted to the spindle end, with the indicator on the outboard surface of the rear hub. 9. Install the anchor plate. 10. Prior to installation of the axle shaft, clean and remove any metallic debris in the hub bolt holes. 11. Inspect the axle shaft for: - cracked material around holes. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Replacement > Page 5718 - oversized holes. 12. Install the axle shaft and new axle shaft bolts. NOTE: Coat the bolt thread with a suitable thread adhesive, if none is present. 13. Hand-tighten the bolts until they seat. 14. On E-350, install the brake drum. 15. Install the tire and wheel assembly. 16. Lower the vehicle after removing the safety stands. 17. On E-350 vehicles, adjust the brakes. For E-Super Duty vehicles, pump the brake to adjust the disc brake calipers. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Replacement > Page 5719 18. Tighten the axle shaft bolts to specification. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Dana Axle Shaft: Specifications Dana Axle Shaft to Hub Bolts ........................................................................................................................................................... 122-163 Nm (90-120 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Dana > Page 5725 Axle Shaft: Specifications Ford 8.8-Inch Ring Gear Maximum Axle Shaft End Play ......................................................................................................................................................... 0.762 mm (0.030 inch) 9.75-Inch Ring Gear Maximum Axle Shaft End ............................................................................................................................................................. 0.762 mm (0.030 inch) Rear Axle Companion Flange Maximum Radial Runout in Assembly ......................................................................................................................................... .......................... 0.305 mm (0.012 inch T.I.R.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Shaft: Service and Repair Dana Removal 1. Remove the axle shaft bolts. ^ Place a drain pan under the rear hub. 2. Remove the axle shaft. 3. Inspect the following components: ^ The rear axle shaft gasket for damage, install new gasket as necessary. ^ The axle shaft for cracks around the bolt holes. Installation 1. NOTE: If the original bolts are being reused, apply a suitable thread adhesive to the bolts. NOTE: Torque specifications are the same for SRW or DRW vehicles. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana > Page 5728 E-350 E-450 Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana > Page 5729 Axle Shaft: Service and Repair Ford 8.8 Inch Ring Gear REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the axle housing cover and drain the lubricant. 4. Remove the rear brake drums. 5. Remove the differential pinion shaft. 1. Remove the differential pinion shaft lock bolt. 2. Remove the differential pinion shaft. 6. Remove the u-washers. 1. Push the axle shafts. 2. Remove the u-washers. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. 7. Remove the two axle shafts. CAUTION: Do not damage the inner wheel bearing oil seal. INSTALLATION 1. Lubricate the lip of the inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana > Page 5730 2. Install the two axle shafts. CAUTION: Do not damage the inner wheel bearing oil seal. 3. Install the u-washers. 1. Position the two u-washers on the button end of the axle shafts. 2. Pull the axle shafts outward. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. 4. Install the differential pinion shaft. 1. Align the hole in the differential pinion shaft with the case lock bolt hole. 2. Install the differential pinion shaft lock bolt. 5. Install the rear brake drums. 6. Install the axle housing cover and fill the rear axle housing with 2.37 liters (5 pints) of Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 7. Clean the wheel hub and mounting surfaces. WARNING: ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE WHEEL HUB OR BRAKE DRUM THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUT TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana > Page 5731 8. Install the tire and wheel assembly. 1. Position the tire and wheel assembly. 2. Install the lug nuts and lower the vehicle. 3. Tighten the lug nuts. 4. Install the center cap. 9.75-Inch Ring Gear REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the axle housing cover. - Drain the lubricant. 4. Remove the rear brake drums. 5. Remove, the differential pinion shaft. 1. Remove the differential pinion shaft lock bolt . 2. Remove the differential pinion shaft. 6. Remove the u-washers. 1. Push the axle shafts inboard. 2. Remove the U-washers. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana > Page 5732 7. Remove the two axle shafts. CAUTION: Do not damage the inner wheel bearing oil seal. INSTALLATION 1. Lubricate the lip of the inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. Install the two axle shafts. CAUTION: Do not damage the inner wheel bearing oil seal. 3. Install the U-washers. 1. Position the two u-washer on the button ends of the axle shafts . Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana > Page 5733 2. Pull the axle shafts outward. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. 4. Install the differential pinion shaft. 1. Align the hole in the differential pinion shaft with the case lock bolt hole. 2. Install a new lock bolt. NOTE: If a new pinion shaft lock bolt is unavailable coat the threads with Thread lock and Sealer EOAZ-19554-FF or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. 5. Install the rear brake drums. 6. Install the axle housing cover and fill the rear axle housing with 2.4 liters (5.5 pints) of Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A 7. Clean the wheel hub and mounting surfaces. WARNING: ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE WHEEL HUB OR BRAKE DRUM THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUT TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. 8. Install the tire and wheel assembly. 1. Position the tire and wheel assembly. 2. Install the lug nuts and lower the vehicle. 3. Tighten the lug nuts. 4. Install the center cap. 9. Lower the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Dana Semi-Floating Axle Seals and Gaskets: Service and Repair Dana Semi-Floating Axle Special Tools Special Tools REMOVAL 1. Remove the axle shaft. 2. Remove and discard the axle shaft oil seal from the axle tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Dana Semi-Floating Axle > Page 5738 NOTE: If only the seal needs to be replaced, it can be pried out of the tube bore. Use care to avoid damaging the seal bore. NOTE: The axle shaft oil seal can be removed with the rear wheel bearing as a unit. 3. Remove the rear wheel bearing. 1. Install the Front Hub Remover/Replacer, the Hub Remover Adapters and the Rear Axle Bearing Remover. 2. Pull the rear rear wheel bearing from the axle tube. WARNING: WEAR SAFETY GLASSES WHEN REMOVING THE REAR WHEEL BEARING. 4. Clean and inspect the rear wheel bearing bore. - Wipe the bore with emery cloth to ensure a smooth surface. - Clean out the bore with a standard metal-cleaning solvent. Wipe this area clean, making sure it is free of dirt or any other contaminants. NOTE: The rear wheel bearing bore must be free from nicks and burrs. If the bore has burrs or spalled areas and a new rear wheel bearing is installed, early failure can result. INSTALLATION 1. Coat the rear wheel bearing with differential lubricant for easier assembly and to prevent possible scoring of the tube bore. 2. Using the Front Hub Remover/Replacer, Hub Remover Adapters, Step Plate and the Rear Axle Bearing Replacer, install the rear rear wheel bearing. NOTE: During bearing installation, make sure the rear wheel bearing is not cocked in the bore. NOTE: Install the rear wheel bearing, with identification numbers on the rear wheel bearing facing out. 3. Using the Front Hub Remover/Replacer, the Hub Remover Adapters, the Step Plate and the Rear Axle Seal Replacer, install a new axle shaft oil Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Dana Semi-Floating Axle > Page 5739 seal. An alternate method of installing the axle shaft oil seal is with the Rear Axle Seal Replacer and Drive Handle. NOTE: Make sure the oil seal is not cocked in the bore during installation. 4. Lubricate the cavity between the lips of the axle shaft oil seal and the rear wheel bearing with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 5. Install the axle shaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Dana Semi-Floating Axle > Page 5740 Seals and Gaskets: Service and Repair Ford 8.8-Inch Ring Gear Special Tools REMOVAL 1. Remove the axle shaft. 2. Use Impact Slide Hammer and Rear Axle Bearing Remover to remove the rear axle bearing and inner wheel bearing oil seal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Dana Semi-Floating Axle > Page 5741 NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged. INSTALLATION 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use Axle Tube Bearing Replacer with Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-l-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Use Axle Tube Seal Replacer with Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shaft. 9.75-Inch Ring Gear Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Dana Semi-Floating Axle > Page 5742 Special Tools REMOVAL 1. Remove the axle shaft. 2. Use the Impact Slide Hammer and the Axle Wheel Bearing Puller to remove the rear wheel bearing and inner wheel bearing oil seal. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged. INSTALLATION 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use the Axle Wheel Bearing Replacer with the Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Dana Semi-Floating Axle > Page 5743 4. Use the Axle Seat Replacer with the Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Dana Semi-Floating Axle > Page 5744 Seals and Gaskets: Service and Repair Leakage Axle shaft oil seals are susceptible to the same kinds of damage as axle drive pinion seals if improperly installed. The seal bore must be clean and the lip handled carefully to avoid cutting or tearing it. The axle shaft journal surface must be free of nicks, gouges, and rough surface texture. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5749 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5750 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5751 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5752 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5753 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5754 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5755 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5756 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5757 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5758 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5759 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5760 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5761 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5762 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5763 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5764 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5765 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5766 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5767 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5768 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5769 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5770 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5771 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5772 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5773 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5774 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5775 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5776 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5777 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5778 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5779 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5780 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5781 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5782 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5783 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5784 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5785 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5786 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5787 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5788 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5789 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5790 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5791 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5792 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5793 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5794 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5795 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5796 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5797 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5798 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5799 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5800 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5801 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5802 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5803 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5804 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5805 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5806 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5807 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5808 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5809 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5810 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5811 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5812 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5813 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5814 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5815 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5816 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5817 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5818 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5819 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5820 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5821 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5822 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5823 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5824 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5825 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5826 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5827 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5828 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5829 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5830 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5831 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5832 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5833 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5834 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5835 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5836 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5837 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5838 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5839 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5840 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5841 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5842 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5843 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Front Wheel Bearing: Specifications Front Lubricate the front wheel bearings. Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Front > Page 5846 Wheel Bearing: Specifications Rear Dana Semi-Floating Axle Lubricate the cavity between the lips of the axle shaft oil seal and the rear wheel bearing with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Ford Axles Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 5847 Wheel Bearing: Description and Operation Part 1 Of 2 Part 2 Of 2 SINGLE REAR WHEEL, E-350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 5848 DUAL REAR WHEEL, E-350 WHEEL HUBS AND BEARINGS The rear hub is supported or floats on the axle spindle on two opposed tapered roller bearings. The rear hub is retained on the spindle by a ratcheting nut that is tabbed to a slot on the spindle. The brake drum is mounted to the rear hub. A seal is installed inboard of the inner rear wheel bearing to keep the rear axle and wheel bearing lubricant from the brake components. The full-floating rear axles on E-350 vehicles have brake drums mounted outboard of the rear hub, permitting brake drum removal for brake inspection without the need to remove the rear hub. The E-Super Duty full-floating axle has rear disc brakes. The rear disc brake rotor is mounted to the rear hub. The rear wheel bearings are packed with a lithium-base grease, Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B, to provide initial lubrication until axle lubricant flows into the rear hubs and rear wheel bearing inner cone and rollers during vehicle operation. Vehicles equipped with Dual Rear Wheel (DRW) rear axles have the wheels attached to the brake drum on the E-350 vehicles or rear hub on E-Super Duty vehicles. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 5849 Wheel Bearing: Testing and Inspection 1. Raise the vehicle until the tire is off the floor. 2. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, adjust the front wheel bearings. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle Wheel Bearing: Service and Repair Dana Semi-Floating Axle Special Tools Special Tools REMOVAL 1. Remove the axle shaft. 2. Remove and discard the axle shaft oil seal from the axle tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 5852 NOTE: If only the seal needs to be replaced, it can be pried out of the tube bore. Use care to avoid damaging the seal bore. NOTE: The axle shaft oil seal can be removed with the rear wheel bearing as a unit. 3. Remove the rear wheel bearing. 1. Install the Front Hub Remover/Replacer, the Hub Remover Adapters and the Rear Axle Bearing Remover. 2. Pull the rear rear wheel bearing from the axle tube. WARNING: WEAR SAFETY GLASSES WHEN REMOVING THE REAR WHEEL BEARING. 4. Clean and inspect the rear wheel bearing bore. - Wipe the bore with emery cloth to ensure a smooth surface. - Clean out the bore with a standard metal-cleaning solvent. Wipe this area clean, making sure it is free of dirt or any other contaminants. NOTE: The rear wheel bearing bore must be free from nicks and burrs. If the bore has burrs or spalled areas and a new rear wheel bearing is installed, early failure can result. INSTALLATION 1. Coat the rear wheel bearing with differential lubricant for easier assembly and to prevent possible scoring of the tube bore. 2. Using the Front Hub Remover/Replacer, Hub Remover Adapters, Step Plate and the Rear Axle Bearing Replacer, install the rear rear wheel bearing. NOTE: During bearing installation, make sure the rear wheel bearing is not cocked in the bore. NOTE: Install the rear wheel bearing, with identification numbers on the rear wheel bearing facing out. 3. Using the Front Hub Remover/Replacer, the Hub Remover Adapters, the Step Plate and the Rear Axle Seal Replacer, install a new axle shaft oil Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 5853 seal. An alternate method of installing the axle shaft oil seal is with the Rear Axle Seal Replacer and Drive Handle. NOTE: Make sure the oil seal is not cocked in the bore during installation. 4. Lubricate the cavity between the lips of the axle shaft oil seal and the rear wheel bearing with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 5. Install the axle shaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 5854 Wheel Bearing: Service and Repair Ford 8.8 Inch Ring Gear Special Tools REMOVAL 1. Remove the axle shaft. 2. Use Impact Slide Hammer and Rear Axle Bearing Remover to remove the rear axle bearing and inner wheel bearing oil seal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 5855 NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged. INSTALLATION 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use Axle Tube Bearing Replacer with Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-l-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Use Axle Tube Seal Replacer with Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shaft. 9.75 Inch Ring Gear Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 5856 Special Tools REMOVAL 1. Remove the axle shaft. 2. Use the Impact Slide Hammer and the Axle Wheel Bearing Puller to remove the rear wheel bearing and inner wheel bearing oil seal. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged. INSTALLATION 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use the Axle Wheel Bearing Replacer with the Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 5857 4. Use the Axle Seat Replacer with the Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub Nut ............................................................................................................................................... ......................................... 88-102 Nm (65-75 ft. lbs.) (Back off 90 degrees, then retighten) ......................................................................................................................................... 20-27 Nm (15-20 ft. lbs.) Maximum Hub Rotating [1] .................................................................................................................. ............................................... 2.3 Nm (20 inch lbs.) [1] Final adjustment is 0 mm (0 inch) end play. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair Center Support: Service and Repair Special Tools DISASSEMBLY 1. Remove the driveshaft. 2. Remove the driveshaft slip-yoke boot. CAUTION: Do not clamp the driveshaft in the jaws of a vise or similar holding fixture. 1. With the front driveshaft on a bench, cut and discard the driveshaft slip yoke boot clamps. 2. Separate the driveshaft slip yoke from the splined stub shaft on the driveshaft. 3. Remove the driveshaft slip-yoke boot. - Inspect the driveshaft slip-yoke boot for damage and replace if required. 4. Inspect the lubricant for contamination. If contaminated, disassemble the driveshaft and inspect the stub shaft and driveshaft slip yoke for wear. Replace as needed. If necessary, separate the coupling shaft from the slip-yoke. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 5866 5. Remove the center bearing retainer, the bracket and the rubber insulator. 1. Remove the driveshaft center bearing retainer. 2. Remove the driveshaft center bearing bracket. 3. Remove the rubber insulator. 6. Using a suitable press, remove the center bearing and bearing retainer off the coupling shaft. 7. Press the dust slinger off the coupling shaft. ASSEMBLY Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 5867 1. Press the dust slinger on the coupling shaft. 2. Install the driveshaft center bearing support. 1. Install the rubber insulator in the driveshaft center bearing bracket. 2. Using a suitable press, install the driveshaft center bearing support assembly onto the coupling shaft. NOTE: Press the bearing on the coupling shaft with the turned-in lip toward the dust slinger. NOTE: The driveshaft center bearing bracket must be installed with the deep flange rearward. 3. Install the driveshaft center bearing retainer. 4. Slide the small opening end of the driveshaft slip-yoke boot on the splined stub shaft as far as it will travel. 5. Install the driveshaft slip yoke boot clamp, and use Keystone Clamp Pliers to crimp the driveshaft slip yoke boot clamp. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 5868 6. Install the driveshaft slip yoke. 1. Lubricate the stub shaft splines, and pull the differential slip yoke boot towards the driveshaft. - Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 2. Fill the differential slip yoke boot with approximately 10 grams of lubricant. - Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 3. Position the driveshaft slip yoke boot clamp. 4. Align the blind splines, and install the driveshaft slip yoke. 7. Install the large driveshaft slip yoke boot clamp. 1. Remove any excess grease from the driveshaft slip yoke boot and driveshaft slip yoke surfaces. 2. Position the differential slip yoke boot over the driveshaft slip yoke boot groove. 3. Position the driveshaft slip yoke to specification from the driveshaft weld to the U-joint centerline. 4. Bleed air from the driveshaft slip yoke boot. 5. Use Keystone Clamp Pliers to crimp the large driveshaft slip yoke boot clamp. 8. Reassemble the coupling shaft. 9. Reinstall the driveshaft assembly in the vehicle. 10. Road test the vehicle. NOTE: If a vibration exists, insert 1.59 mm (1/16 inch) shims between the driveshaft center bearing bracket and support plate (on the bolt ends of the driveshaft center bearing bracket) to reduce compression of the rubber insulator as required. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Service and Repair > 8.8-Inch Ring Gear Companion Flange: Service and Repair 8.8-Inch Ring Gear Special Tools REMOVAL 1. Remove the rear brake drums. NOTE: The rear wheels and brake drums must be removed to prevent brake drag during drive pinion bearing preload adjustment. 2. Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 3. Remove the four driveshaft bolts and disconnect the driveshaft. - Wire the driveshaft out of the way. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5873 4. Install an inch lbs. torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 5. Use Companion Flange Holding Tool to hold the rear axle companion flange while removing the pinion nut. CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation. 6. Mark the driveshaft rear axle companion flange in relation to the drive pinion stem to ensure proper alignment during installation. 7. Use 2-Jaw Puller for Differential Case Bearings to remove the rear axle companion flange. INSTALLATION 1. Lubricate the rear axle companion flange splines. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5874 2. Align the rear axle companion flange with the drive pinion shaft. NOTE: Disregard the scribe marks if a new rear axle companion flange is being installed. 3. With the drive pinion in place in the rear axle housing, install the rear axle companion flange using the Companion Flange Replacer. 4. Position the new pinion nut. 5. Use the Companion Flange Holding Tool to hold the rear axle companion flange while tightening the pinion nut. - Tighten the pinion nut, rotating the pinion occasionally to make sure the cone and roller bearings are seating properly. Take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained by rotating the pinion with an Nm (inch lbs.) torque wrench. - If the original recorded preload is lower than specifications, tighten to the appropriate specifications for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5875 CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. 6. Position the rear driveshaft and align the marks on the rear axle companion flange, 7. Install the four rear driveshaft to rear axle companion flange bolts. 8. Install the rear brake drums. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5876 Companion Flange: Service and Repair 9.75-Inch Ring Gear Special Tools REMOVAL 1. Remove the rear brake drums. NOTE: The rear wheels and brake drums must be removed to prevent brake drag during drive pinion bearing preload adjustment. 2. Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 3. Remove the four driveshaft bolts, and disconnect the driveshaft. Wire the driveshaft out of the way. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5877 4. Install a torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 5. Use a companion flange holding tool to hold the rear axle companion flange while removing the pinion nut. CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation. 6. Mark the driveshaft rear axle companion flange in relation to the drive pinion stem to ensure proper alignment during installation, 7. Use the 2-Jaw Puller for Differential Case Bearings to remove the rear axle companion flange. INSTALLATION 1. Lubricate the rear axle companion flange splines. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A, Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5878 2. Align the rear axle companion flange with the drive pinion shaft. NOTE: Disregard the scribe marks if a new rear axle companion flange is being installed. 3. With the drive pinion in place in the axle housing, install the rear axle companion flange using the Companion Flange Replacer. 4. Position the new pinion nut. 5. Use a suitable companion flange holding tool to hold the rear axle companion flange while tightening the pinion nut. - Tighten the pinion nut, rotating the pinion occasionally to make sure the cone and roller bearings are seating properly. Take frequent cone and Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5879 roller bearing torque preload readings until the original recorded preload readings are obtained by rotating the pinion with a Nm (inch lbs.) torque wrench. - If the original recorded preload is lower than specifications, tighten to the appropriate specification for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preloads. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. 6. Position the rear driveshafts, and align the marks on the rear axle companion flange. 7. Install the four rear driveshaft-to-rear axle companion flange bolts. 8. Install the brake drums. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 00-15-4 > Jul > 00 > Rear Axle, Dana 80,- Whine Noise Technical Service Bulletin # 00-15-4 Date: 000724 Rear Axle, Dana 80,- Whine Noise Article No. 00-15-4 07/24/00 ^ AXLE - REAR AXLE "WHINE" NOISE - VEHICLES EQUIPPED WITH DANA 80 AXLES 5.4L/6.8L VEHICLES BUILT THROUGH 5/24/2000 AND 7.3L VEHICLES BUILT THROUGH 12/18/1999 ^ NOISE - REAR AXLE "WHINE" - VEHICLES EQUIPPED WITH DANA 80 AXLES - 5.4L/6.8L VEHICLES BUILT THROUGH 5/24/2000 AND 7.3L VEHICLES BUILT THROUGH 12/18/1999 FORD: 1996-2000 ECONOLINE ISSUE Some E-450 Super Duty Cutaway/Stripped Chassis vehicles with Dana 80 rear axles may exhibit an excessive amount of axle "whine" noise. Replacement of the axle is not always necessary. Axle whine often is corrected by replacing only the rear driveshaft of the driveshaft assembly with a dampened rear driveshaft. The dampened rear driveshaft should always be installed before the axle is replaced. ACTION Install a dampened rear driveshaft and evaluate for the amount of improvement. If improvement does not meet customer expectation, then replace the axle assembly. Refer to the following Service Procedure for details. FIGURES OF DRIVESHAFT FLANGES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 00-15-4 > Jul > 00 > Rear Axle, Dana 80,- Whine Noise > Page 5888 Figures of rear driveshaft flanges are included in this TSB to aid in determining the correct dampened driveshaft to order. Driveshafts in 1996-1998 model year vehicles had the "Dog Bone" flange (Figure 3) and the "Straight Sided" slip yoke (Figure 5). Driveshafts built Job 1, 1999 to 12/23/1998 have the "Circular" rear flange (Figure 4) and the "Straight Sided" slip yoke (Figure 5). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 00-15-4 > Jul > 00 > Rear Axle, Dana 80,- Whine Noise > Page 5889 Driveshafts built 12/24/1998 and forward have the "Circular" rear flange (Figure 4) and the "Involute Spline" slip yoke (Figure 6). NOTE THE DAMPENED DRIVESHAFT KITS CONTAIN THE REAR DRIVESHAFT, THE SLIP YOKE BOOT, MOUNTING HARDWARE FOR THE SLIP YOKE BOOT AND A 13 mm SPACER. THE 13 mm SPACER MAY BE USED TO LOWER THE CENTER BEARING TO IMPROVE DRIVESHAFT ANGLES IF NEEDED. THE FRAME CROSSMEMBER THAT THE CENTER BEARING ATTACHES TO WAS LOWERED BY 13 mm ON FEBRUARY 21, 1999. DO NOT USE THE 13 mm SPACER ON UNITS BUILT AFTER FEBRUARY 21, 1999. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000, 597997, 702000, 702200, 702300 Service Procedure NOTE DANA MODEL 80 AXLES WERE REPLACED IN PRODUCTION BY DANA MODEL 70 T-RIB AXLES ON: ENGINE/RATIO CHANGE-OVER DATE 7.3L/4.10 December 18, 1999 5.4L/6.8L/4.63 May 22 and 23, 2000 (4.63, Mixed built on the 22nd and 23rd) Hints for determining the type of axle: Dana 80 axles were only used on E-Series units where the 5th position of the VIN is "E" and the 6th position of the VIN is "4" (E40, E45, E47, E49). The parking brake position also provides a way to ensure, that you are working on an E-450. All E-450s have the parking brake at the back of the transmission on the driveshaft. If there is not a parking brake assembly on the driveshaft, the vehicle being worked on is not an E-450 and this TSB does not apply. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 00-15-4 > Jul > 00 > Rear Axle, Dana 80,- Whine Noise > Page 5890 To determine if the axle (2000 model year E-450 only) is a Dana 80 (Figure 1) or Dana T-Rib 70 (Figure 2), look at the pinion flange. CAUTION DO NOT REDUCE PINION BEARING PRELOAD IN AN ATTEMPT TO REDUCE AXLE WHINE. THIS HAS BEEN A COMMON (UNAUTHORIZED) FIELD PRACTICE. REDUCING PINION BEARING PRELOAD MAY RESULT IN REDUCED AXLE DURABILITY. NOTE THE DAMPENED DRIVESHAFT IN THIS TSB IS DESIGNED TO REDUCE THE SOUND LEVEL OF AXLE WHINE CONCERNS. THE DAMPENED DRIVE IS NOT INTENDED FOR OR TO BE USED TO ATTEMPT TO RESOLVE A DRIVELINE VIBRATION CONCERN. 1. Verify the customer concern by road testing the vehicle. HINT: The most common speed ranges where customers have experienced E-450 axle whine are 64-80 km/h (40-50 mph) and 96-112 km/h (60-70 mph). 2. Determine the original wheelbase. The original wheelbase may be found in the lower left corner on the Vehicle Certification Label (Ford Incomplete Vehicle Label). E-450s are built with only a 158 inch or 176 inch wheelbase with a two-piece driveshaft. A large number of E-450s are Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 00-15-4 > Jul > 00 > Rear Axle, Dana 80,- Whine Noise > Page 5891 modified/stretched by second stage manufacturers. Most modifiers that extend the wheelbase do not change the length of the rear driveshaft. NOTE IF THE LENGTH OF THE REAR SHAFT HAS BEEN MODIFIED, A DAMPENED DRIVESHAFT WILL NOT BE AVAILABLE AND REPLACEMENT OF THE AXLE WILL BE THE ONLY AVAILABLE REPAIR. WITHOUT THE DAMPENED DRIVESHAFT, SOME AXLE WHINE MAY STILL BE PRESENT. 3. Order and install dampened Driveshaft Kit (rear shaft only) by application of the original wheelbase. Refer to the Driveshaft Application Table in this TSB. 4. Test drive the vehicle to determine the effectiveness of the dampened driveshaft. If sound is reduced, return the vehicle to the customer. If sound is not reduced to a level that is acceptable to the customer, continue with the service procedure. 5. Replace the rear axle assembly (less brake assemblies) if the vehicle was built before January 1, 2000. Units built after January 1, 2000 have the same level axle assembly that is available in service. Follow repair procedures starting in section 205-02A of the E-Series Workshop Manual for axle assembly removal and installation. NOTE IF THE VEHICLE IS A 1996 TO 1998 MODEL YEAR VEHICLE, THE AXLE FLANGE WILL NEED TO BE EXCHANGED BETWEEN THE NEW AND OLD AXLES. ~HE AXLES MAY ONLY BE BOUGHT WITH THE CURRENT "CIRCULAR FLANGE".) FOLLOW THE INSTRUCTIONS IN SECTION 205-02A (REAR DRIVE AXLE/DIFFERENTIAL - DANA 60, 70 AND 80) WHEN EXCHANGING THE AXLE FLANGE CAUTION ALWAYS INSTALL A NEW WASHER AND PINION/LOCK NUT. ENSURE THAT THE PINION/LOCK NUT IS TORQUED TO 637 Nm (470 LB-FT) 6. Test drive the vehicle to confirm the effectiveness of the repair. NOTE A DAMPENED DRIVESHAFT MAY NOT REDUCE AXLE WHINE IF THE DRIVESHAFT ANGLES ARE EXCESSIVE OR THE DRIVESHAFT ASSEMBLY IS NOT BALANCED OR IS OUT OF PHASE. IF EXCESSIVE AXLE WHINE STILL EXISTS AFTER THE DAMPENED DRIVESHAFT AND IMPROVED AXLE ASSEMBLY IS INSTALLED, ENSURE THAT THE DRIVESHAFT ASSEMBLY DOES NOT HAVE EXCESSIVE ANGLES OR IS OUT OF BALANCE OR PHASE. REFER TO SECTION 205-00 (DRIVELINE SYSTEM - GENERAL INFORMATION) OF THE E-SERIES WORKSHOP MANUAL IF ANY OF THESE CONDITIONS ARE SUSPECTED. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 00-15-4 > Jul > 00 > Rear Axle, Dana 80,- Whine Noise Technical Service Bulletin # 00-15-4 Date: 000724 Rear Axle, Dana 80,- Whine Noise Article No. 00-15-4 07/24/00 ^ AXLE - REAR AXLE "WHINE" NOISE - VEHICLES EQUIPPED WITH DANA 80 AXLES 5.4L/6.8L VEHICLES BUILT THROUGH 5/24/2000 AND 7.3L VEHICLES BUILT THROUGH 12/18/1999 ^ NOISE - REAR AXLE "WHINE" - VEHICLES EQUIPPED WITH DANA 80 AXLES - 5.4L/6.8L VEHICLES BUILT THROUGH 5/24/2000 AND 7.3L VEHICLES BUILT THROUGH 12/18/1999 FORD: 1996-2000 ECONOLINE ISSUE Some E-450 Super Duty Cutaway/Stripped Chassis vehicles with Dana 80 rear axles may exhibit an excessive amount of axle "whine" noise. Replacement of the axle is not always necessary. Axle whine often is corrected by replacing only the rear driveshaft of the driveshaft assembly with a dampened rear driveshaft. The dampened rear driveshaft should always be installed before the axle is replaced. ACTION Install a dampened rear driveshaft and evaluate for the amount of improvement. If improvement does not meet customer expectation, then replace the axle assembly. Refer to the following Service Procedure for details. FIGURES OF DRIVESHAFT FLANGES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 00-15-4 > Jul > 00 > Rear Axle, Dana 80,- Whine Noise > Page 5897 Figures of rear driveshaft flanges are included in this TSB to aid in determining the correct dampened driveshaft to order. Driveshafts in 1996-1998 model year vehicles had the "Dog Bone" flange (Figure 3) and the "Straight Sided" slip yoke (Figure 5). Driveshafts built Job 1, 1999 to 12/23/1998 have the "Circular" rear flange (Figure 4) and the "Straight Sided" slip yoke (Figure 5). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 00-15-4 > Jul > 00 > Rear Axle, Dana 80,- Whine Noise > Page 5898 Driveshafts built 12/24/1998 and forward have the "Circular" rear flange (Figure 4) and the "Involute Spline" slip yoke (Figure 6). NOTE THE DAMPENED DRIVESHAFT KITS CONTAIN THE REAR DRIVESHAFT, THE SLIP YOKE BOOT, MOUNTING HARDWARE FOR THE SLIP YOKE BOOT AND A 13 mm SPACER. THE 13 mm SPACER MAY BE USED TO LOWER THE CENTER BEARING TO IMPROVE DRIVESHAFT ANGLES IF NEEDED. THE FRAME CROSSMEMBER THAT THE CENTER BEARING ATTACHES TO WAS LOWERED BY 13 mm ON FEBRUARY 21, 1999. DO NOT USE THE 13 mm SPACER ON UNITS BUILT AFTER FEBRUARY 21, 1999. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000, 597997, 702000, 702200, 702300 Service Procedure NOTE DANA MODEL 80 AXLES WERE REPLACED IN PRODUCTION BY DANA MODEL 70 T-RIB AXLES ON: ENGINE/RATIO CHANGE-OVER DATE 7.3L/4.10 December 18, 1999 5.4L/6.8L/4.63 May 22 and 23, 2000 (4.63, Mixed built on the 22nd and 23rd) Hints for determining the type of axle: Dana 80 axles were only used on E-Series units where the 5th position of the VIN is "E" and the 6th position of the VIN is "4" (E40, E45, E47, E49). The parking brake position also provides a way to ensure, that you are working on an E-450. All E-450s have the parking brake at the back of the transmission on the driveshaft. If there is not a parking brake assembly on the driveshaft, the vehicle being worked on is not an E-450 and this TSB does not apply. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 00-15-4 > Jul > 00 > Rear Axle, Dana 80,- Whine Noise > Page 5899 To determine if the axle (2000 model year E-450 only) is a Dana 80 (Figure 1) or Dana T-Rib 70 (Figure 2), look at the pinion flange. CAUTION DO NOT REDUCE PINION BEARING PRELOAD IN AN ATTEMPT TO REDUCE AXLE WHINE. THIS HAS BEEN A COMMON (UNAUTHORIZED) FIELD PRACTICE. REDUCING PINION BEARING PRELOAD MAY RESULT IN REDUCED AXLE DURABILITY. NOTE THE DAMPENED DRIVESHAFT IN THIS TSB IS DESIGNED TO REDUCE THE SOUND LEVEL OF AXLE WHINE CONCERNS. THE DAMPENED DRIVE IS NOT INTENDED FOR OR TO BE USED TO ATTEMPT TO RESOLVE A DRIVELINE VIBRATION CONCERN. 1. Verify the customer concern by road testing the vehicle. HINT: The most common speed ranges where customers have experienced E-450 axle whine are 64-80 km/h (40-50 mph) and 96-112 km/h (60-70 mph). 2. Determine the original wheelbase. The original wheelbase may be found in the lower left corner on the Vehicle Certification Label (Ford Incomplete Vehicle Label). E-450s are built with only a 158 inch or 176 inch wheelbase with a two-piece driveshaft. A large number of E-450s are Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 00-15-4 > Jul > 00 > Rear Axle, Dana 80,- Whine Noise > Page 5900 modified/stretched by second stage manufacturers. Most modifiers that extend the wheelbase do not change the length of the rear driveshaft. NOTE IF THE LENGTH OF THE REAR SHAFT HAS BEEN MODIFIED, A DAMPENED DRIVESHAFT WILL NOT BE AVAILABLE AND REPLACEMENT OF THE AXLE WILL BE THE ONLY AVAILABLE REPAIR. WITHOUT THE DAMPENED DRIVESHAFT, SOME AXLE WHINE MAY STILL BE PRESENT. 3. Order and install dampened Driveshaft Kit (rear shaft only) by application of the original wheelbase. Refer to the Driveshaft Application Table in this TSB. 4. Test drive the vehicle to determine the effectiveness of the dampened driveshaft. If sound is reduced, return the vehicle to the customer. If sound is not reduced to a level that is acceptable to the customer, continue with the service procedure. 5. Replace the rear axle assembly (less brake assemblies) if the vehicle was built before January 1, 2000. Units built after January 1, 2000 have the same level axle assembly that is available in service. Follow repair procedures starting in section 205-02A of the E-Series Workshop Manual for axle assembly removal and installation. NOTE IF THE VEHICLE IS A 1996 TO 1998 MODEL YEAR VEHICLE, THE AXLE FLANGE WILL NEED TO BE EXCHANGED BETWEEN THE NEW AND OLD AXLES. ~HE AXLES MAY ONLY BE BOUGHT WITH THE CURRENT "CIRCULAR FLANGE".) FOLLOW THE INSTRUCTIONS IN SECTION 205-02A (REAR DRIVE AXLE/DIFFERENTIAL - DANA 60, 70 AND 80) WHEN EXCHANGING THE AXLE FLANGE CAUTION ALWAYS INSTALL A NEW WASHER AND PINION/LOCK NUT. ENSURE THAT THE PINION/LOCK NUT IS TORQUED TO 637 Nm (470 LB-FT) 6. Test drive the vehicle to confirm the effectiveness of the repair. NOTE A DAMPENED DRIVESHAFT MAY NOT REDUCE AXLE WHINE IF THE DRIVESHAFT ANGLES ARE EXCESSIVE OR THE DRIVESHAFT ASSEMBLY IS NOT BALANCED OR IS OUT OF PHASE. IF EXCESSIVE AXLE WHINE STILL EXISTS AFTER THE DAMPENED DRIVESHAFT AND IMPROVED AXLE ASSEMBLY IS INSTALLED, ENSURE THAT THE DRIVESHAFT ASSEMBLY DOES NOT HAVE EXCESSIVE ANGLES OR IS OUT OF BALANCE OR PHASE. REFER TO SECTION 205-00 (DRIVELINE SYSTEM - GENERAL INFORMATION) OF THE E-SERIES WORKSHOP MANUAL IF ANY OF THESE CONDITIONS ARE SUSPECTED. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 5901 Drive/Propeller Shaft: Specifications Driveshaft Angle to Horizontal: Spring (@ Pad): 2450: 5.4 L ..................................................................................................................................................... .................... 5.65 @ Empty Angle Degree 6.8, 7.3 L .......................................................................... ........................................................................................ 5.90 @ Empty Angle Degree 2775: 5.4 L ..................................................................................................................................................... .................... 6.10 @ Empty Angle Degree 6.8, 7.3 L .......................................................................... ........................................................................................ 6.37 @ Empty Angle Degree Transmission Angle to Horizontal (At All Conditions): Wheel Base (All) .................................................................................................................................. ....................................................................... 4.1° Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 5902 Drive/Propeller Shaft: Description and Operation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 5903 Part 1 Of 2 Part 2 Of 2 NOTE: Whenever the vehicle is raised on a hoist, inspect the universal joint slip yoke seal for rips or holes. Replace if required. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 5904 The driveshaft is a tubular shaft which transfers torque from the engine, through the transmission to the rear axle. Driveshafts differ in length, diameter, and type of slip yoke to accommodate various wheelbase and powertrain combinations. The E-Super Duty vehicle has a two-piece driveshaft that is supported by a driveshaft center bearing support mounted to the frame. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 5905 Drive/Propeller Shaft: Testing and Inspection 1. Road test the vehicle to determine the critical vibration points. Note the road speed, the engine RPM, and the shift lever positions at which the vibration occurs. 2. Stop the vehicle, place the transmission lever in neutral and run the engine through the critical speed ranges determined in Step 1. 3. If no vibration is felt, balance the driveshaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Installation Drive/Propeller Shaft: Service and Repair Removal and Installation One Piece REMOVAL 1. Raise and support the vehicle. 2. To maintain driveline balance, index the driveshaft flange yoke to the rear axle universal joint flange. 3. Remove the driveshaft. 1. Remove the four driveshaft-to-driveshaft rear axle companion flange bolts, and lower the driveshaft. 2. Slide the driveshaft rearward off the transmission output shaft. - Plug the extension housing to prevent fluid loss. NOTE: Index-mark the slip yoke to transmission output shaft. INSTALLATION 1. Follow the removal procedure in reverse order. 2. Inspect the extension housing seal for damage. Replace if necessary. 3. Lubricate the slip-yoke spline with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Installation > Page 5908 4. Install the driveshaft-to-driveshaft rear axle companion flange bolts. Two Piece REMOVAL 1. Raise and support the vehicle. 2. Index the driveshaft to the rear axle universal joint flange. 3. Remove four bolts, and disconnect and remove the rear driveshaft section. 4. Support the coupling shaft, and remove the two center bearing bracket retaining bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Installation > Page 5909 5. Lock the parking brake. 6. Remove the coupling shaft bolts from the parking brake assembly by removing the four U-joint retainer bolts. 7. Separate the coupling shaft from the parking brake assembly. NOTE: If the output flange on the parking brake assembly needs replacing, refer to parking brake. INSTALLATION 1. Position the driveshaft, using the index marks. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Installation > Page 5910 2. Install the U-Joint caps and bolts. - Release the parking brake. 3. Support the coupling shaft, and position the center bearing and bracket. 4. Install the center bearing bracket bolts. 5. Install the rear driveshaft section. 6. Install the four driveshaft-to-rear axle bolts. 7. Remove the supports, and lower the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Installation > Page 5911 Drive/Propeller Shaft: Service and Repair Indexing NOTE: If driveshaft components are replaced and driveshaft vibration is encountered after installation, index the driveshaft. NOTE: If indexing the driveshaft does not eliminate the vibration, balance the driveshaft. 1. Raise and support the vehicle. 2. Disconnect the rear driveshaft. 3. Rotate the rear axle flange. 4. Connect the driveshaft. 5. Lower the vehicle and test drive. 6. Repeat the procedure if necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Installation > Page 5912 Drive/Propeller Shaft: Service and Repair Runout and Balance 1. Use a twin post axle contact hoist to raise and support the vehicle. 2. Remove the rear wheels and tires. Install the lug nuts to retain the brake drums. 3. Note and record base line speed. - With the transmission in gear, increase the vehicle speed to the maximum vibration level. Note and record the speed of this vibration period as a base line speed. CAUTION: To prevent overheating, do not run the vehicle on the hoist for an extended period. 4. Check the attachment of the driveshaft to the rear axle flange. Replace any worn parts. 5. Check the driveshaft for out of balance. 1. With the transmission in gear, run the vehicle with the driveshaft rotating 64-80 km/h (40-50 mph). 2. Have an assistant barely contact the driveshaft with a marker in the rear, middle, and front end to indicate heavy spots. WARNING: KEEP HANDS AWAY FROM THE BALANCE WEIGHTS WHILE THE DRIVESHAFT IS ROTATING. 6. Balance the driveshaft. 1. Install two stainless steel screw-type hose clamps on the driveshaft with the clamp screws opposite the mark. 2. Tighten the hose clamps starting at the pinion yoke end of the driveshaft. 7. Run the vehicle at the base line speed. 8. If the vibration is still evident, rotate the clamps away from each other until balanced and test. 9. If necessary, continue to rotate the clamps apart in smaller increments and test. If the vibration still exists, repeat the procedure at the front of the driveshaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Installation > Page 5913 10. Install the tire and wheel assembly. 1. Position the tire and wheel assembly. 2. Install the lug nuts. 3. Lower the vehicle and tighten the lug nuts. 4. Install the center cap. 11. Road test the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 05-26-10 > Dec > 05 > Driveline Clunk/Bump Starting From A Stop Slip Yoke: Customer Interest Driveline - Clunk/Bump Starting From A Stop TSB 05-26-10 12/31/05 CLUNK OR BUMP WHEN STARTING FROM A STOP FORD: 1997-2004 F-150 1997-2006 E-Series 1999-2006 F-Super Duty This article supersedes TSB 04-26-6 to update the affected model years. ISSUE Some 1997-2006 E-Series, 1999-2006 F-Super Duty, 1997-2003 F-150 and 2004 F-150 Heritage 4x2 vehicles may exhibit a driveline clunk or bump that occurs as the vehicle starts to move forward, following a stop. This condition may be caused by the slip yoke not sliding smoothly on the output shaft splines. ACTION Lubricate the slip yoke with Motorcraft PTFE Lubricant. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Verify the condition. 2. Remove the driveshaft per Workshop Manual Section 205-01. Be sure to index-mark the driveshafi during removal to maintain alignment during reinstallation. 3. Lubricate the slip yoke with 7-13 grams (0.25-0.46 oz.) of Motorcraft PTFE Lubricant. 4. Re-index and reinstall the driveshafi per Workshop Manual. 5. Verify the repair. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052610A 1997-2003 F-150 and 2004 1.0 Hrs. F-150 Heritage: Lubricate Driveshaft Slip-Yoke (Includes Time For Road Test To Verify Concern, Driveshaft R and I, And Road Test To Verify Repair) 052610A 1997-2006 E-Series and 1.2 Hrs. 1999-2006 F-Super Duty: Lubricate Driveshaft Slip-Yoke (Includes Time For Road Test To Verify Concern, Driveshaft R and I, And Road Test To Verify Repair) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 05-26-10 > Dec > 05 > Driveline Clunk/Bump Starting From A Stop > Page 5922 DEALER CODING CONDITION BASIC PART NO. CODE 4602 41 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 05-26-10 > Dec > 05 > Driveline - Clunk/Bump Starting From A Stop Slip Yoke: All Technical Service Bulletins Driveline - Clunk/Bump Starting From A Stop TSB 05-26-10 12/31/05 CLUNK OR BUMP WHEN STARTING FROM A STOP FORD: 1997-2004 F-150 1997-2006 E-Series 1999-2006 F-Super Duty This article supersedes TSB 04-26-6 to update the affected model years. ISSUE Some 1997-2006 E-Series, 1999-2006 F-Super Duty, 1997-2003 F-150 and 2004 F-150 Heritage 4x2 vehicles may exhibit a driveline clunk or bump that occurs as the vehicle starts to move forward, following a stop. This condition may be caused by the slip yoke not sliding smoothly on the output shaft splines. ACTION Lubricate the slip yoke with Motorcraft PTFE Lubricant. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Verify the condition. 2. Remove the driveshaft per Workshop Manual Section 205-01. Be sure to index-mark the driveshafi during removal to maintain alignment during reinstallation. 3. Lubricate the slip yoke with 7-13 grams (0.25-0.46 oz.) of Motorcraft PTFE Lubricant. 4. Re-index and reinstall the driveshafi per Workshop Manual. 5. Verify the repair. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052610A 1997-2003 F-150 and 2004 1.0 Hrs. F-150 Heritage: Lubricate Driveshaft Slip-Yoke (Includes Time For Road Test To Verify Concern, Driveshaft R and I, And Road Test To Verify Repair) 052610A 1997-2006 E-Series and 1.2 Hrs. 1999-2006 F-Super Duty: Lubricate Driveshaft Slip-Yoke (Includes Time For Road Test To Verify Concern, Driveshaft R and I, And Road Test To Verify Repair) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 05-26-10 > Dec > 05 > Driveline - Clunk/Bump Starting From A Stop > Page 5928 DEALER CODING CONDITION BASIC PART NO. CODE 4602 41 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Page 5929 Slip Yoke: Service and Repair Special Tools DISASSEMBLY 1. Remove the driveshaft slip yoke boot. 1. With the front driveshaft on a bench, cut and discard the driveshaft slip yoke boot clamps. 2. Separate the driveshaft slip yoke from the splined stub shaft on the driveshaft. CAUTION: Do not clamp the driveshaft in the jaws of a vise or similar holding fixture. 2. Remove the driveshaft slip yoke boot. - Inspect the driveshaft slip yoke boot for damage and replace if required. 3. Inspect the lubricant for contamination. If contaminated, disassemble the driveshaft and inspect the stub shaft and driveshaft slip yoke for wear. Replace as needed. ASSEMBLY Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Page 5930 1. Slide the small opening end of the driveshaft slip yoke boot on the splined stub shaft as far as it will travel. 2. Install the driveshaft slip yoke boot clamp and use Keystone Clamp Pliers to crimp the driveshaft slip yoke boot clamp. 3. Install the driveshaft slip yoke. 1. Lubricate the stub shaft splines, and pull the driveshaft slip yoke boot towards the driveshaft. - Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 2. Fill the driveshaft slip yoke boot with approximately 10 grams of lubricant. - Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 3. Position the large driveshaft slip yoke boot clamp. 4. Align the blind splines, and install the driveshaft slip yoke. 4. Install the large driveshaft slip yoke boot clamp. 1. Remove any excess grease from the driveshaft slip yoke boot and driveshaft slip yoke surfaces. 2. Position the driveshaft slip yoke boot over the driveshaft slip yoke boot groove. 3. Position the driveshaft slip yoke to specification from the driveshaft weld to the U-joint centerline. 4. Bleed air from the driveshaft slip yoke boot. 5. Use Keystone Clamp Pliers to crimp the large driveshaft slip yoke boot clamp. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Specifications Universal Joint: Specifications U-Joint Bolts ........................................................................................................................................ .......................................... 21-27 Nm (15-20 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Specifications > Page 5934 Universal Joint: Description and Operation The universal joints are: lubed-for-life design. - 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. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Specifications > Page 5935 Universal Joint: Testing and Inspection Place the vehicle on a frame hoist and rotate the driveshaft by hand. Check for rough operation or seized U-joints. Replace the U-joint if it shows signs of seizure, excessive wear, or improper seating. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke - Disassembly and Assembly Universal Joint: Service and Repair Single Cardan, Flange Yoke - Disassembly and Assembly DISASSEMBLY 1. Remove the driveshaft. 2. Place the driveshaft on a suitable workbench, being careful not to damage the tube. CAUTION: Do not clamp the driveshaft in a vise or similar holding fixture. 3. Mark the positions of the driveshaft components. NOTE: If components are not marked and installed correctly, driveline imbalance can occur. 4. Clamp the U-Joint Tool in a vise. 5. Remove all four of the snap rings. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke - Disassembly and Assembly > Page 5938 6. Remove the driveshaft flange yoke. 1. Position the driveshaft flange yoke in the U-Joint Tool. 2. Press out a bearing cup. 3. Remove the driveshaft flange yoke. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the driveshaft flange yoke. 7. Remove the spider. 1. Reposition the driveshaft in the U-Joint Tool. 2. Press out the bearing cup. 3. Rotate the driveshaft. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the spider. 8. Clean the yoke area at the end of the driveshaft. ASSEMBLY 1. Install the spider. 1. Start a new bearing cup into the driveshaft yoke. 2. Position the new spider in the driveshaft yoke. 3. Position the driveshaft in the U-Joint Tool. 4. Press the bearing cup below the yoke surface. - Repeat for the other bearing cup. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke - Disassembly and Assembly > Page 5939 2. Install the driveshaft flange yoke. 1. Start a new bearing cup into the driveshaft flange yoke. 2. Position the driveshaft flange yoke. 3. Position the driveshaft in the U-Joint Tool. 4. Press the bearing cup below the yoke surface. - Repeat for the other bearing cup. 3. Remove the driveshaft from the U-Joint Tool, and install the four snap rings. NOTE: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. 4. Check the U-joints for freedom of movement. - If binding, strike the yoke with a brass or plastic hammer. NOTE: Do not strike the bearings. 5. Install the driveshaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke - Disassembly and Assembly > Page 5940 Universal Joint: Service and Repair Single Cardan, Slip Yoke - Disassembly and Assembly DISASSEMBLY 1. Place the driveshaft on a suitable workbench. Be careful not to damage the tube. CAUTION: Under no circumstances is the driveshaft assembly to be clamped in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing driveshaft failure during vehicle operation. 2. Index-mark the driveshaft components. NOTE: If components are not marked and therefore installed incorrectly, driveline imbalance can occur. 3. Clamp U-Joint Tool in a vise. 4. Remove the snap rings. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke - Disassembly and Assembly > Page 5941 5. Remove the driveshaft slip yoke. 1. Position the driveshaft slip yoke in the U-Joint Tool. 2. Press out a bearing cup. 3. Rotate the driveshaft slip yoke. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the driveshaft slip yoke. NOTE: If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed out all the way. 6. Repeat Step 5 to remove the remaining bearing cups and spider from the driveshaft. 7. Clean the yoke area at each end of the driveshaft. ASSEMBLY 1. Install the bearing cup. 1. Start a new bearing cup into the driveshaft yoke. 2. Position the new spider in the driveshaft yoke. 3. Using the U-Joint Tool, press the bearing cup below the yoke surface. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke - Disassembly and Assembly > Page 5942 2. Remove the driveshaft from the U-Joint Tool, and install the snap ring. NOTE: Use the yellow snap rings supplied in the kit to assemble the rear axle shaft universal joint (U-joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. 3. Repeat Steps 1 and 2 to install the remaining new bearing cups, spider, and driveshaft yoke. 4. Check the U-joints for freedom of movement. - If binding, strike the yoke with a brass or plastic hammer. NOTE: Do not strike the bearings. 5. Install the driveshaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications TORQUE SPECIFICATIONS Flywheel Bolts: 73-87 Nm (54-64 ft. lbs.) Flywheel Inspection Cover: 30-39 Nm (22-29 ft. lbs.) TORQUE SEQUENCES Romeo Engines Windsor Engines Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5946 Flex Plate: Testing and Inspection 1. Inspect the flywheel for: ^ cracks (A). ^ worn ring gear teeth (B). ^ chipped or cracked ring gear teeth (C). ^ Replace the flywheel if any of the above exist. 2. Inspect the flywheel ring gear runout. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5947 Flex Plate: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the transmission. NOTE: It is not necessary to remove the transmission from the jack. 3. Remove the bolts and the flywheel. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection For testing procedures for the Transmission Control Indicator Lamp (TCIL), please refer to Pinpoint Test C in Automatic Transmission/Transaxle / Testing and Inspection / Procedures / External Control Diagnostics. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 1. Place the transmission range selector lever into MANUAL 1 position, then back to the (D) position. 2. Hang a three-pound weight on the transmission range selector lever. 3. Center the pointer in the middle of the (D) position. - Rotate the thumb wheel, located on the bottom of the steering column, to adjust the pointer. 4. Remove the weight. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5961 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5962 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5963 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5964 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5965 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5966 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5967 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5968 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5969 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5970 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5971 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5972 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5973 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5974 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5975 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5976 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5977 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5978 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5979 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5980 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5981 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5982 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5983 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5984 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5985 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5986 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5987 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5988 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5989 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5990 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5991 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5992 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5993 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5994 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5995 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5996 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5997 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5998 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5999 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6001 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6002 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6003 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6004 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6005 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6006 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6007 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6008 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6009 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6010 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6011 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6012 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6013 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6014 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6015 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6016 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6017 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6018 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6019 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6020 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6021 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6022 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6023 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6024 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6025 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6026 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6027 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6028 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6029 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6030 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6031 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6032 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6033 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6034 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6035 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6036 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6037 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6038 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6039 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6040 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6041 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6042 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6043 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6044 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6045 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6046 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6047 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6048 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6049 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6050 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6051 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6052 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6053 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6054 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6055 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation Overdrive Switch: Description and Operation The Transmission Control Switch (TCS) and Transmission Control Indicator Lamp (TCIL) are located inside the end of the gearshift lever. Pushing the TCS will either disengage or engage the overdrive function of the transmission. When overdrive is disengaged, the TCIL will illuminate the word OFF. Each time the ignition switch is placed in the RUN position, the transmission will automatically provide overdrive operation regardless of TCS position the last time the vehicle was running. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Page 6061 Overdrive Switch: Testing and Inspection For testing procedures for the Transmission Control Switch (TCS), please refer to Pinpoint Test C in Automatic Transmission/Transaxle / Testing and Inspection / Procedures / External Control Diagnostics. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Mode Switch: Service and Repair TRANSMISSION MODE SWITCH REMOVAL 1. Remove the Transmission Control (TC) switch. 1. Remove the TC switch cover. 2. Remove the TC switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor .............................................................................................................................................. 8-10 Nm (75-85 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 6068 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 6069 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 6070 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 6071 Transmission Position Switch/Sensor: Service and Repair Special Tools REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1. Remove the bolts. 2. Remove the sensor. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 6072 1. Install the digital transmission range (TR) sensor. 1. Install the sensor. 2. Loosely install the bolts. 2. Install the Digital Transmission Range (TR) Sensor Alignment Tool. NOTE: Make sure that the manual control lever is in the neutral position. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 6073 5. Reconnect the connector. 6. Reconnect the battery ground cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Sensor Transmission Speed Sensor: Locations Output Shaft Speed Sensor Transmission View The Output Shaft Speed Sensor is located under the vehicle, on left side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Sensor > Page 6078 Transmission Speed Sensor: Locations Turbine Speed Sensor The Turbine Shaft Speed Sensor is located under the vehicle, on right side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Page 6079 Output Shaft Speed Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications Shift Interlock Solenoid: Specifications TORQUE SPECIFICATIONS Brake Shift Interlock Solenoid Bolts ........................................................................................................................................ 7-11 Nm (62-97 inch lbs.) Shift Lock Actuator Bolts ......................................................................................................................................................... 7-11 Nm (62-97 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 6086 Shift Interlock Solenoid: Service and Repair REMOVAL 1. Disconnect the battery. WARNING: ON VEHICLES EQUIPPED WITH AN AUXILIARY BATTERY, BOTH THE NEGATIVE AND POSITIVE BATTERY CABLES MUST BE DISCONNECTED. WARNING: ON VEHICLES EQUIPPED WITH A 7.3L, ENGINE, BOTH THE PRIMARY AND SECONDARY BATTERIES MUST BE DISCONNECTED. 2. Remove the instrument panel steering column cover, the driver side knee brace and the instrument panel steering column opening cover reinforcement. 3. Disconnect all necessary harness connectors and separate the harness bracket from the steering column. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 6087 4. Remove the shift indicator cable and position it aside. 5. Remove the nuts and lower the steering column. 6. Remove the shift lock actuator and disconnect the harness connector. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 6088 1. Follow the removal procedure in reverse order. 2. Make sure the shift cable and the shift indicator cable are properly adjusted. Verify shift lock actuator operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection For testing procedures for the Transmission Control Indicator Lamp (TCIL), please refer to Pinpoint Test C in Automatic Transmission/Transaxle / Testing and Inspection / Procedures / External Control Diagnostics. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 1. Place the transmission range selector lever into MANUAL 1 position, then back to the (D) position. 2. Hang a three-pound weight on the transmission range selector lever. 3. Center the pointer in the middle of the (D) position. - Rotate the thumb wheel, located on the bottom of the steering column, to adjust the pointer. 4. Remove the weight. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Description and Operation Overdrive Switch: Description and Operation The Transmission Control Switch (TCS) and Transmission Control Indicator Lamp (TCIL) are located inside the end of the gearshift lever. Pushing the TCS will either disengage or engage the overdrive function of the transmission. When overdrive is disengaged, the TCIL will illuminate the word OFF. Each time the ignition switch is placed in the RUN position, the transmission will automatically provide overdrive operation regardless of TCS position the last time the vehicle was running. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Description and Operation > Page 6102 Overdrive Switch: Testing and Inspection For testing procedures for the Transmission Control Switch (TCS), please refer to Pinpoint Test C in Automatic Transmission/Transaxle / Testing and Inspection / Procedures / External Control Diagnostics. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Mode Switch: Service and Repair TRANSMISSION MODE SWITCH REMOVAL 1. Remove the Transmission Control (TC) switch. 1. Remove the TC switch cover. 2. Remove the TC switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor .............................................................................................................................................. 8-10 Nm (75-85 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 6109 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 6110 Transmission Position Switch/Sensor: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 6111 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 6112 Transmission Position Switch/Sensor: Service and Repair Special Tools REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1. Remove the bolts. 2. Remove the sensor. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 6113 1. Install the digital transmission range (TR) sensor. 1. Install the sensor. 2. Loosely install the bolts. 2. Install the Digital Transmission Range (TR) Sensor Alignment Tool. NOTE: Make sure that the manual control lever is in the neutral position. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Specifications > Page 6114 5. Reconnect the connector. 6. Reconnect the battery ground cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Sensor Transmission Speed Sensor: Locations Output Shaft Speed Sensor Transmission View The Output Shaft Speed Sensor is located under the vehicle, on left side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Sensor > Page 6119 Transmission Speed Sensor: Locations Turbine Speed Sensor The Turbine Shaft Speed Sensor is located under the vehicle, on right side of transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 > Page 6120 Output Shaft Speed Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Instrument Panel Views The 4 Wheel Anti-Lock Brakes Relay is located behind the center of instrument panel, on 4 wheel anti-lock brakes relay. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations > Page 6126 4 Wheel Anti_Lock Brake System Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Diagnostic Connector - ABS: Locations NOTE: There are TWO diagnostic test connectors in this system. Ford uses varying terminology for these connectors but you can identify them by connector number and by location. - The first test connector is the black RABS Diagnostic Test Connector C208. This primary test connector is used to retrieve and clear codes. Instrument Panel Views The Rear Anti-Lock Brake System Diagnostic Connector C208 is located below RH side of instrument panel. - The second test connector is the Differential Speed Sensor (DSS) Data Link Connector (DLC) C242. This connector is used only when instructed Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 6130 to by a procedure in a pinpoint test. The Differential Speed Sensor (DSS) Data Link Connector (DLC) C242 is located at the left side of the instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Rear Anti-Lock Brakes Electronic Brake Control Module: Specifications Rear Anti-Lock Brakes TORQUE SPECIFICATIONS Anti-Lock Brake Control Module Screws .................................................................................................................................. 2-3 Nm (17-26 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Rear Anti-Lock Brakes > Page 6135 Electronic Brake Control Module: Specifications 4-Wheel Anti-Lock Brakes TORQUE SPECIFICATIONS Anti-Lock Brake Control Module Screws ................................................................................................................................................. .................................. 4-5 Nm (36-44 inch lbs.) To Bracket Bolts ........................................................ .......................................................................................................... 30-40 Nm (22-29 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Rear Antilock Brake (RABS) Module Electronic Brake Control Module: Locations Rear Antilock Brake (RABS) Module Instrument Panel Views The Rear Anti-Lock Brake System Module is located behind center side of the instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Rear Antilock Brake (RABS) Module > Page 6138 Electronic Brake Control Module: Locations 4 Wheel Anti-Lock Brake System Module Engine Compartment Views The 4 Wheel Anti-Lock Brakes Module is located on the LH front frame rail. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Four Wheel Antilock Brakes 4 Wheel Anti_Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Four Wheel Antilock Brakes > Page 6141 Rear Anti_Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) Electronic Brake Control Module: Service and Repair Four Wheel Anti-Lock Brake System (4WABS) REMOVAL 1. Remove the electronic hydraulic control unit (EHCU). 2. Detach the bracket from the EHCU. 1 Remove the bolts. 2 Detach the bracket from the EHCU. 3. Remove the anti-lock brake control module. 1 Remove the screws. 2 Remove the anti-lock brake control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6144 Electronic Brake Control Module: Service and Repair Rear Antilock Brake System (RABS) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the engine cover. 3. Remove the anti-lock brake control module. 1 Remove the screw. 2 Lower the module assembly. 3 Remove the nuts. 4 Disconnect the electrical connector. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6145 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to driven 16 km ( 10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Hydraulic Assembly Hydraulic Control Assembly - Antilock Brakes: Specifications Hydraulic Assembly TORQUE SPECIFICATIONS Hydraulic Control Unit Bracket To Inner Fender Well Nuts ................................................................................................................................. ................................ 24-31 Nm (18-23 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Hydraulic Assembly > Page 6150 Hydraulic Control Assembly - Antilock Brakes: Specifications Solenoid Valve Body TORQUE SPECIFICATIONS Rear Antilock Brake Valve Nuts ................................................................................................................................................ 21-29 Nm (15-21 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Assembly Bleeding NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been replaced or if the HCU lines have been opened. 1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 2. Connect a clear waste line to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 3. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 6153 4. Tighten the RH rear bleeder screw, and disconnect the waste line. 5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw, in that order. 6. Connect the NGS DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the NGS instructions. 7. Repeat the system bleed procedure as outlined in Steps 1 through 5. Replacement REMOVAL WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. 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. Disconnect the battery ground cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 6154 2. Position the radiator coolant recovery reservoir aside. 1 Remove the bolts. 2 Position the radiator coolant recovery reservoir aside. 3. Remove the bolts and position the power steering pump reservoir aside. NOTE: Do not disconnect the hose from the power steering pump reservoir. 4. Disconnect the brake lines from the brake master cylinder. 5. Disconnect the brake lines. 1 Remove the 7/16-24 brake lines. 2 Disconnect the 1/2-20 brake lines. NOTE: Plug each port of the electronic hydraulic control unit (EHCU) to prevent brake fluid from spilling. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 6155 6. Disconnect the anti-lock brake control module electrical connector. 1 Lift the lock tab upward. 2 Disconnect the anti-lock brake control module electrical connector. 7. Remove the EHCU bracket to inner fender well nuts. 8. Remove the EHCU. 1 Disconnect the anti-lock brake control module electrical connectors. 2 Remove the EHCU. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 6156 1. To install, reverse the removal procedure. 2. Bleed the EHCU after installation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 6157 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Solenoid Valve Body REMOVAL 1. Remove the RABS valve. 1 Disconnect the electrical connector 2 Remove the hydraulic lines and plug them. 3 Remove the nuts. 4 Remove the RABS valve. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. INSTALLATION RABS Valve Installation 1. To install, reverse the removal procedure. - Bleed the brakes. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6158 Bleeding Components Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Rear Anti-Lock Brakes Wheel Speed Sensor: Specifications Rear Anti-Lock Brake Sensor Pole Piece To Rear Anti-Lock Brake Sensor Indicator Clearance 0.005-0.045 in Rear Anti-Lock Brake Sensor Bolt 25-29 ft.lb Rear Anti-Lock Brake Sensor Nuts 15-21 ft.lb Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Rear Anti-Lock Brakes > Page 6163 Wheel Speed Sensor: Specifications Front Anti-Lock Brake Sensor Bolt 62-80 in.lb Front Anti-Lock Brake Sensor Wire Retaining Bolt 7-9 ft.lb Rear Anti-Lock Sensor Bolt 25-29 ft.lb Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Rear Axle Speed Sensor Wheel Speed Sensor: Locations Rear Axle Speed Sensor Full Body Views The Rear Axle Speed Sensor is located below the rear of vehicle, mounted on differential. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Rear Axle Speed Sensor > Page 6166 Wheel Speed Sensor: Locations Wheel Speed Sensor Left Front Full Body Views The Left Front Wheel Sensor is located behind LH front wheel. Right Front Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Rear Axle Speed Sensor > Page 6167 Full Body Views The Right Front Wheel Sensor is located near right front wheel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring Wheel Speed Sensor: Service and Repair Toothed Ring Front REMOVAL 1. Remove the front disc brake rotor. 2. Use 2-3 Jaw Puller to remove the front anti-lock brake sensor indicator. CAUTION: Discard the front anti-lock brake sensor indicator. INSTALLATION 1. Use an appropriate size cylinder and press to install the front anti-lock brake sensor indicator. CAUTION: The front anti-lock brake sensor indicator must be pressed on straight. 2. Install the front disc brake rotor. Rear For removal and installation of the rear brake anti-lock sensor indicator, refer to Differential. NOTE: The rear anti-lock brake sensor indicator is attached to the ring gear. It is necessary to remove the ring gear in order to remove the rear anti-lock brake sensor indicator. Rear Antilock Brake System (RABS) For removal and installation of the rear brake anti-lock sensor indicator, refer to Differential. NOTE: The rear anti-lock brake sensor indicator is attached to the ring gear. It is necessary to remove the ring gear in order to remove the rear anti-lock brake sensor indicator. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 6170 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Rear Antilock Brake System REMOVAL 1. Raise and support the vehicle. 2. Remove the rear anti-lock brake sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. CAUTION: Do not get dirt in the rear axle housing. INSTALLATION 1. Clean and inspect the rear anti-lock brake sensor. 1 Clean the rear axle housing mounting surface. 2 Inspect and clean the magnetized sensor pole piece. 3 Inspect the sensor and O-ring for damage. Replace if necessary. 4 Lightly lubricate the O-ring with motor oil. CAUTION: Do not get dirt in the rear axle housing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 6171 2. Measure the clearance between the rear anti-lock brake sensor pole piece and the rear anti-lock brake sensor indicator. 3. Install the rear anti-lock brake sensor. 1 Position the sensor and install the bolt. NOTE: Do not apply force to the plastic rear anti-lock brake sensor connector. The rear anti-lock brake sensor flange should slide to the mounting surface. 2 Connect the electrical connector. Front REMOVAL 1. Remove the front disc brake rotor. 2. Detach the front anti-lock brake sensor wire from the front brake hose. 1 Disconnect the front anti-lock brake sensor electrical connector. 2 Detach the front anti-lock brake sensor wire from the front brake hose. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 6172 3. Remove the bolt. 4. Remove the front anti-lock brake sensor. 1 Remove the front anti-lock brake sensor bolts. 2 Remove the front anti-lock brake sensor. INSTALLATION 1. To install, reverse the removal procedure. Rear REMOVAL 1. Raise and support vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 6173 2. Remove the rear anti-lock brake sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. INSTALLATION CAUTION: Use care not to get dirt in the rear axle housing. 1. Clean and inspect the rear anti-lock brake sensor. 1 Clean the axle mounting surface. 2 Inspect and clean the rear anti-lock brake sensor. 3 Inspect the rear anti-lock brake sensor O-ring for damage. Replace if necessary. 4 Lightly lubricate the rear anti-lock brake sensor O-ring with Synthetic SAE 75W 140 Rear Axle Lubricant F1TZ-19580-A or equivalent meeting Ford specification WSL-M2C192-A. 2. Install the rear anti-lock brake sensor. 1 Position the rear anti-lock brake sensor and install the bolt. 2 Connect the electrical connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 6174 CAUTION: Do not apply force to the plastic rear anti-lock brake sensor connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Page 6175 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure Brake Bleeding: Service and Repair Caliper Bleeding Procedure 1. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. 2. Have an assistant pump the brake pedal (BP) and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 6180 Brake Bleeding: Service and Repair Manual Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Place a box end wrench on the RH rear 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 brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear bleeder screw. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 6181 6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw. 7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front disc brake caliper bleeder screw. 11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 6182 Brake Bleeding: Service and Repair Master Cylinder Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 any part of the hydraulic system has been disconnected for repair or replacement, air can enter the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. - When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines. 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir, and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 4. Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 5. If the brake master cylinder is being primed at the bench, install it in the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 6183 6. Remove the short brake tubes, and install the brake outlet tubes. 7. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal. 2 Loosen the rearmost brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten 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 at the front brake tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 6184 Brake Bleeding: Service and Repair Pressure Bleeding 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 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 3. Place a box end wrench on the RH rear 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 brake fluid. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 6185 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS) NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been replaced or if the HCU lines have been opened. 1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 2. Connect a clear waste line to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 3. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear bleeder screw, and disconnect the waste line. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 6186 5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw, in that order. 6. Connect the NGS DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the NGS instructions. 7. Repeat the system bleed procedure as outlined in Steps 1 through 5. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Bleeder Screws 13-18 ft.lb Disc Brake Caliper Bolts 16-30 ft.lb Front Caliper Anchor Plate Bolts 141-191 ft.lb Front Brake Hose-to-Caliper Flow Bolt 23-29 ft.lb Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Bleeding Brake Caliper: Service and Repair Bleeding 1. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. Repeat until clear bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Bleeding > Page 6193 Brake Caliper: Service and Repair Front Anchor Plate Removal 1. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1. Remove the two front disc brake caliper anchor plate bolts. 2. Remove the front disc brake caliper anchor plate. Installation 1. Install the front disc brake caliper anchor plate. 1. Position the front disc brake caliper anchor plate. 2. Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Disassembly and Assembly DISASSEMBLY 1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper 3. Secure the disc brake caliper in a vise. 4. Remove the caliper pistons. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper. 3 Force out the caliper pistons to the block of wood. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Bleeding > Page 6194 4 Remove the block of wood and the caliper piston. 5. Remove and discard the piston seals and boots. 6. If the disc brake caliper is leaking, replace the piston seals. If the caliper bores are excessively scored or corroded, replace the disc brake caliper. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores. ASSEMBLY 1. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. CAUTION: Never reuse piston seals or dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. 2. Install the caliper pistons. 1 Install the piston seal. 2 Install the piston boot. 3 Insert the caliper piston. CAUTION: Be careful not to damage or dislodge the piston seal. 4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston. 3. Install the disc brake caliper. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Bleeding > Page 6195 Removal and Installation REMOVAL WARNING: - BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. - ASBESTOS FIBER DUST CAN BE PRESENT ON BRAKE AND CLUTCH ASSEMBLIES AND IS HAZARDOUS TO HEALTH IF INHALED. - BRAKE AND CLUTCH ASSEMBLIES MUST BE CLEANED USING A VAC WM CLEANER RECOMMENDED FOR USE WITH ASBESTOS FIBERS, SUCH AS A BRAKE/CLUTCH/SERVICE VACUUM. THE BAG MUST BE LABELED IN ACCORDANCE WITH OSHA INSTRUCTIONS, SEALED, AND THE TRASH HAULER NOTIFIED AS TO THE BAG'S CONTENTS. - IF A VACUUM SUITABLE FOR ASBESTOS IS NOT AVAILABLE, CLEANING MUST BE DONE WET. IF DUST GENERATION IS STILL POSSIBLE, TECHNICIANS MUST WEAR GOVERNMENT-APPROVED TOXIC DUST PURIFYING RESPIRATORS. - THE OCCUPATIONAL HEALTH AND SAFETY ACT (OSHA) REQUIRES AREAS WHERE ASBESTOS DUST GENERATION IS POSSIBLE TO BE ISOLATED AND POSTED WITH WARNING SIGNS. ONLY TECHNICIANS PERFORMING BRAKE OR CLUTCH REPAIR ARE TO BE PRESENT IN THE AREA. 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. If so equipped, unclip the speed sensor wiring from the front brake hose. 4. Disconnect the front brake hose from the disc brake caliper. 1 Remove the flow bolt. 2 Disconnect the front brake hose. 3 Remove and discard the copper washers. CAUTION: To prevent contamination and reduce air entry, always plug a disconnected front brake hose. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Bleeding > Page 6196 5. Remove the two disc brake caliper bolts. 6. Remove the disc brake caliper from the front disc brake caliper anchor plate. 7. Inspect the disc brake caliper for brake fluid leakage. If the disc brake caliper is leaking, it must be rebuilt or replaced. INSTALLATION 1. Fill the rubber caliper sleeve boots with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. CAUTION: To prevent deterioration of the caliper sleeve boots, do not use petroleum-based lubricant. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Bleeding > Page 6197 2. Install the disc brake caliper and the front brake hose. 1 Position the disc brake caliper in the front disc brake caliper anchor plate. 2 Install and tighten the disc brake caliper bolts. 3 Using new copper washers, install the front brake hose and the bolt. 3. If so equipped, attach the speed sensor wiring to the front brake hose. 4. Bleed the brake system. 5. Install the wheel and tire assembly. 6. Inspect the brake system operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Min. Thickness Above Backing Plate Or Rivets 0.039 in Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 6201 Brake Pad: Service and Repair REMOVAL WARNING: - BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. - ASBESTOS FIBER DUST CAN BE PRESENT ON BRAKE AND CLUTCH ASSEMBLIES AND IS HAZARDOUS TO HEALTH IF INHALED. - BRAKE AND CLUTCH ASSEMBLIES MUST BE CLEANED USING A VACUUM CLEANER RECOMMENDED FOR USE WITH ASBESTOS FIBERS, SUCH AS A BRAKE/CLUTCH/SERVICE VACUUM. THE BAG MUST BE LABELED IN ACCORDANCE WITH OSHA INSTRUCTIONS, SEALED, AND THE TRASH HAULER NOTIFIED AS TO THE BAG'S CONTENTS. - IF A VACUUM SUITABLE FOR ASBESTOS IS NOT AVAILABLE, CLEANING MUST BE DONE WET. IF DUST GENERATION IS STILL POSSIBLE, TECHNICIANS MUST WEAR GOVERNMENT-APPROVED TOXIC DUST PURIFYING RESPIRATORS. - THE OCCUPATIONAL HEALTH AND SAFETY ACT (OSHA) REQUIRES AREAS WHERE ASBESTOS DUST GENERATION IS POSSIBLE TO BE ISOLATED AND POSTED WITH WARNING SIGNS. ONLY TECHNICIANS PERFORMING BRAKE OR CLUTCH REPAIR ARE TO BE PRESENT IN THE AREA. 1. If new pads are to be installed, provide space for the brake fluid displaced from the disc brake caliper. - Remove and discard enough brake fluid from the brake master cylinder to allow room for the brake fluid displaced when the caliper piston is pressed to the bottom of the caliper bore. 2. Raise and support the vehicle. 3. Remove the tire and wheel assembly. 4. If so equipped, unclip the speed sensor wiring from the front brake hose. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 6202 5. Remove the two disc brake caliper bolts. 6. Remove the disc brake caliper from the front disc brake caliper anchor plate. CAUTION: Do not allow the disc brake caliper to hang from the front brake hose. Use wire to support the disc brake caliper from a convenient underbody component. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 6203 7. Inspect: - the disc brake caliper for brake fluid leakage. If the disc brake caliper is leaking, it must be rebuilt or replaced. - the pad thickness. Do not install pads worn to or past the specified thickness above the metal backing plate or rivets. - the pads for contamination. Do not put oil or grease-contaminated pads into service. - the front disc brake hub and rotor for minimum thickness. Replace the front disc brake hub and rotor if worn to or below minimum thickness. INSTALLATION 1. If installing new pads, use a C-clamp and a pad to press the caliper piston to the bottom of the caliper bore. NOTE: Bottoming of the caliper piston is not necessary if reusing the original pads. 2. Fill the rubber caliper sleeve boots with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. CAUTION: To prevent deterioration of the caliper sleeve boots, do not use petroleum-based lubricant. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 6204 3. Install the disc brake caliper. 1 Position the disc brake caliper in the front disc brake caliper anchor plate. 2 Install and tighten the disc brake caliper bolts. 4. If so equipped, attach the speed sensor wiring to the front brake hose. 5. Install the tire and wheel assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment Technical Service Bulletin # 98-5A-5 Date: 980318 Hub-Mount Brake Rotor Machining Equipment Article No. 98-5A-5 03/18/98 ^ BRAKES - AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT ^ BRAKE ROTOR MACHINING - AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1993-98 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE: Hub-mount brake rotor machining equipment from Rotunda is now approved for warranty and service use. Brake roughness consists of one or more of the following symptoms while braking: ^ Steering wheel vibration/nibble ^ vibration ^ Brake pedal pulsation Brake roughness is caused by: ^ Uneven rotor wear known as Disc Thickness Variation (DTV). DTV is caused by excessive Lateral Run-Out (LRO) or overtorqued wheel lug nuts ^ Non-uniform lining transfer ACTION: Use Rotunda Hub-Mount Lathe / Pro-Cut (201-00002) to service vehicles with brake roughness. The hub-mount lathe removes DTV, lining transfer, and on-vehicle rotor LRO. The hub-mount lathe has the following advantages over caliper-mount lathes: ^ Improved rotor LRO and "dishing" tolerances ^ Ability to machine rear rotors on live axles, except for trucks with dual rear wheels ^ Easier set-up Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 6209 Refer to the Service Procedure for details. PART NUMBER PART NAME F6AZ-9L494-AA High Temperature Nickel Anti-Seize Lubricant OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-4-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 702300, 703000, 703400 Service Procedure 1. Verify concern. 2. Pre-checks to include: ^ Check OASIS and TSBs for vehicle-specific brake/vibration concerns ^ Visually inspect suspension bushings/ball joints ^ Visually inspect tire conditions and pressure ^ Check wheel bearing end-play 3. Remove wheel/tire. 4. Remove caliper. 5. For vehicles with two-piece hub/rotor: a. Mark rotor and wheel stud for proper indexing during reassembly. b. Remove rotor. NOTE: THE ROTOR MUST HAVE SUFFICIENT THICKNESS AFTER MACHINING TO BE OVER THE MINIMUM THICKNESS SPECIFICATION C 6. Measure rotor thickness and record measurement. Replace rotor if below the minimum thickness specification cast in the rotor. CAUTION: DO NOT USE ABRASIVE SANDING DISC SINCE IT WILL REMOVE METAL FROM MOUNTING SURFACES AND ADVERSELY AFFECT 7. Remove corrosion from wheel mounting surface, both rotor mounting surfaces, and hub mounting surface. A die grinder with a Scotchbrite(R) surfa 8. For vehicles with two-piece hub/rotor, reinstall rotor onto hub, aligning with marks from Step 5a. NOTE: READ THE ENTIRE OPERATING MANUAL AND VIEW THE VIDEO SHIPPED WITH THE LATHE BEFORE INSTALLING, OPERATING, OR SERVICING THE LATHE. 9. Machine rotors using the Rotunda Hub-Mount Brake Lathe / Pro-Cut (201-00002). a. Install hub adapter and silencer belt (where applicable). b. Install cutting lathe. NOTE: TOTAL INDICATED READING (TIR) TARGET IS 0.000 mm, MAXIMUM IS O.O6 mm (0.003"). c. Adjust lathe oscillation using a dial indicator. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 6210 NOTE: DEPTH OF CUT SHOULD BE BETWEEN 0.10 AND O.2O mm (0.004 AND 0.008"). LIGHTER CUTS WILL CAUSE THE BIT TO HEAT UP A d. Center cutting head, adjust cutting bits, install chip deflector. e. Machine rotor. f. Measure and record rotor thickness. NOTE: TARGET LRO IS 0.000 mm, MAXIMUM IS O.05 mm (0.002"). g. Install dial indicator, measure and record rotor LRO. Remove dial indicator. h. Remove lathe and silencer belt. 10. Remove metal shavings. 11. Remove the adapter. 12. For vehicles with two-piece hub/rotors: a. Remove rotor from hub. b. Remove metal shavings from hub and rotor mounting surfaces and from ABS sensors. c. Apply High Temperature Nickel Anti-Seize Lubricant (F6AZ-9L494-AA) to hub mounting surface to prevent future corrosion. d. Match marks on rotor and hub and assemble rotor to hub. 13. Install pads and calipers. NOTE: USING AN IMPACT TOOL WITHOUT AN ACCUTORO(R) SOCKET WILL LEAD TO UNEVENLY TORQUED LUG NUTS. THIS CAUSES ROTOR 14. Install wheels using impact guns equipped with Rotunda AccuTorq(R) sockets. Use a torque wrench on locking lug nuts. 15. Check brake operation before returning to customer. Support Telephone Numbers 1. Lathe Administration Support: (800) 768-8632 2. Pro-Cut Technical Support: (800) 543-6618 Reference list for Pro-Cut car labor operations: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 6211 ^ A = Aspire ^ B = Escort/Tracer ^ C = Probe ^ D = Contour/Mystique ^ E = Mustang ^ F = Taurus/Sable ^ G = Thunderbird/Cougar ^ H = Crown Victoria/Grand Marquis ^ I = Continental ^ J = Mark VIII ^ K = Town Car ^ L = Festiva ^ M = Tempo/Topaz Reference list for Pro-Cut light truck labor operations: ^ AA = Villager ^ AB = Windstar ^ AC = Aerostar 4X2 ^ AD = Aerostar 4X4 ^ AE = Ranger 4X2 ^ AF = Ranger 4X4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 6212 ^ AG = Explorer/Mountaineer 4X2 ^ AH = Explorer/Mountaineer 4X4 ^ AI = Econoline ^ AJ = F-250 HD/F-350 4X2 ^ AK = F-250 HD/F-350 4X4 ^ AL = F-Super Duty ^ AM = F-150/F-250 LD 4X2 ^ AN = F-150/F-250 LD 4X4 And Bronco ^ AO = Expedition/Navigator 4X2 ^ AP = Expedition/Navigator 4X4 ^ AQ = Super Duty F Series Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc Brake Rotor/Disc: Specifications Brake Rotor/Disc Minimum Thickness 1.102 in Brake Disc Maximum Runout 0.003 in Brake Disc Maximum Thickness Variation 0.0004 in Minimum Thickness 1.102 in Brake Disc Maximum Runout 0.003 in Brake Disc Maximum Thickness Variation 0.0004 in Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc > Page 6215 Brake Rotor/Disc: Specifications Disc Backing Plate TORQUE SPECIFICATIONS Brake Disc Shield Bolts .......................................................................................................................................................... 9-12 Nm (80-106 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc Brake Rotor/Disc: Service and Repair Brake Rotor/Disc REMOVAL 1. Remove the front disc brake caliper anchor plate. 2. Remove the front disc brake hub and rotor as follows: 1 Remove the hub grease cap. 2 Remove the cotter pin. 3 Remove the nut retainer. 4 Remove the spindle nut. 5 Remove the front wheel outer bearing retainer washer. 6 Remove the outer front wheel bearing. 7 Remove the front disc brake hub and rotor. 3. If necessary, resurface the front disc brake hub and rotor. Ford recommends on-vehicle rotor machining. Follow the lathe manufacturer's instructions. 1 Remove the wheel hub grease seal. 2 Remove the inner front wheel bearing. INSTALLATION 1. Thoroughly clean and inspect the front wheel bearings and the front disc brake hub and rotor. - Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent. 2. Lubricate the front wheel bearings. - Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 6218 3. Install a new wheel hub grease seal. 1 Install the inner front wheel bearing. 2 Install a new wheel hub grease seal. 4. Install the front disc brake hub and rotor. 1 Position the front disc brake hub and rotor. 2 Install the outer front wheel bearing. 3 Install the front wheel outer bearing retainer washer. 4 Install the spindle nut. 5. While rotating the front disc brake hub and rotor, tighten the spindle nut. 6. Loosen the spindle nut two turns. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 6219 7. Tighten the spindle nut while rotating the front disc brake hub and rotor. 8. Loosen the spindle nut. 9. Tighten the spindle nut while rotating the front disc brake hub and rotor. 10. Install the following components: 1 Install the nut retainer. 2 Install the cotter pin. 3 Install the hub grease cap. 11. Install the front disc brake caliper anchor plate. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 6220 Brake Rotor/Disc: Service and Repair Disc Backing Plate REMOVAL 1. Remove the rotor. 2. Remove the front disc brake rotor shield. - Remove the three front disc brake rotor shield bolts and remove the front disc brake rotor shield. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications TORQUE SPECIFICATIONS Brake Backing Plate Nuts .................................................................................................................................................... 54.5-68.1 Nm (40-50 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 6225 Backing Plate: Service and Repair REMOVAL 1. Remove the rear brake shoes and linings. 2. Remove the axle shaft or the axle shaft and rear hub, if so equipped. 3. Compress the cable retainer and pull the parking brake rear cable and conduit from the brake backing plate. 4. Remove the rear wheel cylinder. 1 Disconnect the brake line fitting. 2 Remove the two rear wheel cylinder bolts. 3 Remove the rear wheel cylinder. 5. Remove the four backing plate-to-axle flange nuts and bolts and the brake backing plate. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 6226 1. Follow the removal procedure in reverse order. 2. Bleed the brake system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Rear Drum Brake Dana 60 Axle - 9.75" Ring Gear Maximum Diameter ............................................................................................................................. ................................... 12.210" in. ( 310.13 mm. ) Dana 70 Axle - 10.50" Ring Gear - 8000 lbs. Axle Capacity Maximum Diameter ............................................................................................................................. ................................... 12.209" in. ( 310.10 mm. ) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 6230 Brake Drum: Service and Repair REMOVAL WARNING: - ASBESTOS FIBER DUST CAN BE PRESENT ON BRAKE AND CLUTCH ASSEMBLIES AND IS HAZARDOUS TO HEALTH IF INHALED. - BRAKE AND CLUTCH ASSEMBLIES MUST BE CLEANED USING A VACUUM CLEANER RECOMMENDED FOR USE WITH ASBESTOS FIBERS, SUCH AS A BRAKE/CLUTCH/SERVICE VACUUM. THE BAG MUST BE LABELED PER OSHA INSTRUCTIONS, SEALED, AND THE TRASH HAULER NOTIFIED AS TO THE BAG'S CONTENTS. - IF A VACUUM SUITABLE FOR ASBESTOS IS NOT AVAILABLE. CLEANING MUST BE DONE WET. IF DUST GENERATION IS STILL POSSIBLE, TECHNICIANS MUST WEAR GOVERNMENT-APPROVED TOXIC DUST PURIFYING RESPIRATORS. - THE OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) REQUIRES AREAS WHERE ASBESTOS DUST GENERATION IS POSSIBLE TO BE ISOLATED AND POSTED WITH WARNING SIGNS ONLY TECHNICIANS PERFORMING BRAKE OR CLUTCH REPAIR ARE TO BE PRESENT IN THE AREA. - TO REDUCE THE POSSIBILITY OF UNEVEN BRAKING, ALWAYS REPLACE REAR BRAKE SHOES AND LININGS AT BOTH ENDS OF AN AXLE. 1. Remove the wheel and ore assembly. 2. Remove the brake drum. 1 Remove and discard the spring nut. 2 Pull the brake drum off the axle shaft. CAUTION: Use of a brake drum puller or a torch Is not recommended. Brake drum distortion can result. NOTE: If the brake drum is rusted to the axle shaft pilot diameter, tap the center of the brake drum between the lug bolts. 3. If brake drums will not come off, follow these steps. 1 Using a screwdriver, move the brake shoe adjusting lever off the brake adjuster screw. 2 Use the Brake Adjustment Tool to loosen the brake shoe adjusting screw nut. NOTE: Move the adjustment tool handle downward to loosen the brake shoe adjusting screw nut. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 6231 4. Using the Brake Drum Micrometer, measure the brake drum inside diameter. - Replace the brake drum if the maximum inside diameter exceeds the specification molded on the brake drum. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Lining Minimum Thickness Standard 1/32 in Heavy Duty 1/32 in Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Drums Installed Brake Shoe: Adjustments Drums Installed This vehicle is equipped with self-adjusting drum brake mechanisms which require no manual adjustment. The brakes are adjusted as necessary whenever the service brakes are applied. 1. Raise and support the vehicle. 2. At the back of the brake backing plate, remove the brake adjusting hole cover. 3. Rotate the brake shoe adjusting screw nut. 1 Using a screwdriver, move the brake shoe adjusting lever off the brake shoe adjusting screw nuts 2 Turn the brake shoe adjusting screw nut until the brake drum begins to drag. Then loosen the brake adjuster screw until the brake drum rotates freely. NOTE: Move the adjustment tool handle upward to tighten the brake adjuster screw. 4. Replace the brake adjusting hole cover 5. Lower the vehicles Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Drums Installed > Page 6237 Brake Shoe: Adjustments Drums Removed WARNING: - ASBESTOS FIBER DUST CAN BE PRESENT ON BRAKE AND CLUTCH ASSEMBLIES AND IS HAZARDOUS TO HEALTH IF INHALED. - BRAKE AND CLUTCH ASSEMBLIES MUST BE CLEANED USING A VACUUM CLEANER RECOMMENDED FOR USE WITH ASBESTOS FIBERS, SUCH AS A BRAKE CLUTCH/SERVICE VACUUM. THE BAG MUST BE LABELED PER OSHA INSTRUCTIONS, SEALED, AND THE TRASH HAULER NOTIFIED AS TO THE BAG'S CONTENTS. - IF A VACUUM SUITABLE FOR ASBESTOS IS NOT AVAILABLE' GLEANING MUST BE DONE WET. IF DUST GENERATION IS STILL POSSIBLE, TECHNICIANS MUST WEAR GOVERNMENT-APPROVED TOXIC DUST PURIFYING RESPIRATORS. - THE OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) REQUIRES AREAS WHERE ASBESTOS DUST GENERATION IS POSSIBLE TO BE ISOLATED AND POSTED WITH WARNING SIGNS. ONLY TECHNICIANS PERFORMING BRAKE OR CLUTCH REPAIR ARE TO BE PRESENT IN THE AREA. NOTE: After adjusting the rear brake shoes and linings, check the parking brake for proper operation. Make sure the parking brake cable equalizer operates freely. 1. Measure the brake drum inside diameter - Use a brake adjustment gauge 2. Adjust the rear brake shoes and linings. - Rotate the brake adjuster screw until the rear brake shoes and linings touch the tool. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty Brake Shoe: Service and Repair Heavy-Duty REMOVAL WARNING: - ASBESTOS FIBER DUST CAN BE PRESENT ON BRAKE AND CLUTCH ASSEMBLIES AND IS HAZARDOUS TO HEALTH IF INHALED. - BRAKE AND CLUTCH ASSEMBLIES MUST BE CLEANED USING A VACUUM CLEANER RECOMMENDED FOR USE WITH ASBESTOS FIBERS SUCH AS THE BRAKE/CLUTCH/SERVICE VACUUM. THE BAG MUST BE LABELED PER OSHA INSTRUCTIONS, SEALED, AND THE TRASH HAULER NOTIFIED AS TO THE BAG'S CONTENTS. - IF A VACUUM SUITABLE FOR ASBESTOS IS NOT AVAILABLE, CLEANING MUST BED DONE WET. IF DUST GENERATION IS STILL POSSIBLE, TECHNICIANS MUST WEAR GOVERNMENT-APPROVED TOXIC DUST PURIFYING RESPIRATORS - THE OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) REQUIRES AREAS WHERE ASBESTOS DUST GENERATION IS POSSIBLE TO BE ISOLATED AND POSTED WITH WARNING SIGNS. ONLY TECHNICIANS PERFORMING BRAKE OR CLUTCH REPAIR ARE TO BE PRESENT IN THE AREA. - TO REDUCE THE POSSIBILITY OF UNEVEN BRAKING, ALWAYS REPLACE REAR BRAKE SHOES AND LININGS AT BOTH ENDS OF AN AXLE. 1. Remove the brake drum. 2. Inspect the rear brake assembly for the following: - the rear wheel cylinder for excessive leakage that can contaminate brake system parts, and rebuild as necessary. - the rear brake shoes and linings for contamination, and replace as necessary. - the rear brake shoes and linings for minimum thickness above backing plate or rivers. and replace as necessary. - the springs for heat discoloration, and replace as necessary. 3. Remove the brake shoe retracting spring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 6240 4. Disconnect the parking brake lever. 1 Remove the parking brake lever bolt lock nut at the back of the brake backing plate and the parking brake lever bolt. 2 Remove the parking brake rear cable and conduit from the parking brake lever. 5. Remove the parking brake lever. 6. Remove the adjusting screw assembly. 1 Disconnect the brake shoe adjusting lever cable from the brake shoe adjusting lever. 2 Remove the brake shoe adjusting lever cable 3 Remove the cable guide. 4 Remove the adjusting lever return spring and the brake shoe adjusting lever. 5 Remove the brake shoe adjusting screw spring. 6 Remove the brake adjuster screw assembly. 7. Remove the rear brake shoe and lining. 1 Remove the brake shoe anchor pin guide plate. 2 Remove the brake shoe hold-down springs and the brake shoe hold-down spring pins. 3 Remove the rear brake shoes and linings. INSTALLATION 1. Lubricate the brake backing plate friction points Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 6241 2. Install the rear brake shoes and linings. 1 Position the rear brake shoes and linings. 2 Install the brake shoe hold-down spring pins and the brake shoe hold-down springs. 3 Install the brake shoe anchor pin guide plate. 3. Assemble the brake adjuster screw assembly. 1 Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171. 2 Install the brake adjuster screw into the brake shoe adjusting screw nut to the end of the threads, and then loosen one-half turn. 3 Install the brake shoe adjusting screw socket on the brake shoe adjusting screw nut. NOTE: To prevent incorrect installation. the socket end of each brake adjuster screw is stamped R or L. 4. Install the brake adjuster screw assembly 1 Position the brake adjuster screw assembly. 2 Install the brake shoe adjusting screw spring. 3 Position the brake shoe adjusting lever cable. 4 Install the cable guide. 5 Position the adjusting lever return spring and the brake shoe adjusting lever. 6 Hook the brake shoe adjusting lever cable to the brake shoe adjusting lever. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 6242 5. Test the operation of the automatic self-adjuster. 1 Pull the brake shoe adjusting lever cable and check that the brake shoe adjusting lever rotates the brake shoe adjuster assembly. 2 Release the brake shoe adjusting lever cable and check that the brake shoe adjusting lever advances to the next notch on the brake shoe adjusting screw nut. 6. Install the parking brake lever. 1 Attach the parking brake rear cable and conduit to the parking brake lever. 2 Position the parking brake lever 3 Install the parking brake lever bolt and, at the back of the brake backing plate, the parking brake lever bolt lock nut. 7. Install the brake shoe retracting spring. 8. Adjust the brakes. 9. Install the brake drum. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 6243 Brake Shoe: Service and Repair Standard REMOVAL 1. Remove the brake drum. 2. Inspect the rear brake assembly for the following: - the rear wheel cylinder for excessive leakage that can contaminate brake system parts, and rebuild as necessary. - the rear brake shoes and linings for contamination, and replace as necessary - the rear brake shoes and linings for minimum thickness, above the backing plate or rivets, and replace as necessary. - the springs for heat discoloration, and replace as necessary. - the adjusting lever contact with the brake adjuster screw. 3. Remove the brake shoe retracting springs 1 Remove the long brake shoe retracting spring. 2 Remove the short brake shoe retracting spring. NOTE: To aid installation, note the locations of the short and long brake shoe retracting springs. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 6244 4. Remove the adjusting screw assembly. 1 Disconnect the brake shoe adjusting lever cable from the brake shoe adjusting lever. 2 Remove the brake shoe adjusting lever cable. 3 Remove the cable guide. 4 Remove the adjusting lever return spring and the brake shoe adjusting lever. 5 Remove the brake shoe adjusting screw spring. 6 Remove the brake adjuster screw assembly 5. Remove the brake shoe anchor pin guide plate, parking brake strut and the parking brake lever pin retainer. NOTE: The parking brake link spring and the brake parking spring retainer will come off with the parking brake strut. 6. Remove the rear brake shoes and linings. 1 Remove the brake shoe hold-down springs. 2 Remove the rear brake shoes and linings. 3 Remove the brake shoe hold-down spring pins Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 6245 7. Pull back the parking brake cable spring and disconnect the parking brake lever. INSTALLATION 1. Compress the parking brake cable spring and attach the parking brake lever. 2. Clean and lubricate the brake backing plate. - Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. 3. Attach the parking brake lever to the rear brake shoe and lining and secure the parking brake lever pin retainer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 6246 4. Install the rear brake shoes and linings. 1 Position the rear brake shoes and linings 2 Install the brake shoe hold-down spring pins and the brake shoe hold-down springs 5. Install the parking brake strut. 1 Install the parking brake link spring and the parking brake spring retainer on the parking brake strut. 2 Install the parking brake strut. 3 Install the brake shoe anchor pin guide plate. 6. Install the short brake shoe retracting spring. 1 Place the brake shoe adjusting lever cable over the anchor pin, with crimped side in. 2 Install the short brake shoe retracting spring. 7. Install the long brake shoe retracting spring. 1 Install the cable guide. 2 Position the brake shoe adjusting lever came in the cable guide groove. 3 Install the long brake shoe retracting spring NOTE: Make sure the brake shoe adjusting lever cable is positioned in the cable guide groove. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 6247 8. Assemble the brake adjuster screw assembly. 1 Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. 2 Install the brake adjuster screw into the brake shoe adjusting screw nut to the end of the threads, and then loosen one-half turn. 3 Install the brake shoe adjusting screw socket on the brake shoe adjusting screw nut. NOTE: To prevent incorrect installation, the socket end of each brake adjuster screw is stamped R or L. 9. Install the brake adjuster screw assembly. 1 Position the brake adjuster screw assembly 2 Install the brake shoe adjusting screw spring. 3 Position the brake shoe adjusting lever cable. 4 Position the adjusting lever return spring and the brake shoe adjusting lever. 5 Hook the brake shoe adjusting lever cable to the brake shoe adjusting lever. 10. Test the operation of the automatic self-adjuster. 1 Pull the brake shoe adjusting lever cable and check that the brake shoe adjusting lever rotates the brake shoe adjuster assembly. 2 Release the brake shoe adjusting lever cable and check that the brake shoe adjusting lever advances to the next notch on the brake shoe adjusting screw nut. 11. Adjust the brakes. 12. Install the brake drum. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Page 6248 Brake Shoe: Tools and Equipment Special Tools Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Bleeder Screw 62-79 in.lb Rear Wheel Cylinder Bolts 9-13 ft.lb Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation Wheel Cylinder: Service and Repair Removal and Installation REMOVAL 1. Remove the brake shoes and linings. 2. Remove the rear wheel cylinder. 1 Disconnect the brake line fitting. 2 Remove the two rear wheel cylinder bolts. 3 Remove the rear wheel cylinder. INSTALLATION 1. Follow the removal procedure in reverse order. 2. Bleed the brake system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 6254 Wheel Cylinder: Service and Repair Disassembly And Assembly DISASSEMBLY 1. Disassemble the rear wheel cylinder. 1 Remove the rubber boots. 2 Remove the rear wheel cylinder pistons 3 Remove the cups. 4 Remove the expander. 5 Remove the wheel cylinder bleeder screw from the rear wheel cylinder. NOTE: Removal is not necessary to disassemble. inspect, hone or overhaul the rear wheel cylinder. ASSEMBLY 1. Follow the disassembly procedure in reverse order NOTE: Coat all the rear wheel cylinder parts with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure Brake Bleeding: Service and Repair Caliper Bleeding Procedure 1. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. 2. Have an assistant pump the brake pedal (BP) and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 6260 Brake Bleeding: Service and Repair Manual Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Place a box end wrench on the RH rear 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 brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear bleeder screw. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 6261 6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw. 7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front disc brake caliper bleeder screw. 11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 6262 Brake Bleeding: Service and Repair Master Cylinder Bleeding WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 any part of the hydraulic system has been disconnected for repair or replacement, air can enter the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. - When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines. 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir, and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 4. Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 5. If the brake master cylinder is being primed at the bench, install it in the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 6263 6. Remove the short brake tubes, and install the brake outlet tubes. 7. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal. 2 Loosen the rearmost brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten 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 at the front brake tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 6264 Brake Bleeding: Service and Repair Pressure Bleeding 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 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 3. Place a box end wrench on the RH rear 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 brake fluid. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 6265 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS) NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been replaced or if the HCU lines have been opened. 1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 2. Connect a clear waste line to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 3. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear bleeder screw, and disconnect the waste line. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 6266 5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw, in that order. 6. Connect the NGS DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the NGS instructions. 7. Repeat the system bleed procedure as outlined in Steps 1 through 5. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Bleeder Screws 13-18 ft.lb Disc Brake Caliper Bolts 16-30 ft.lb Front Caliper Anchor Plate Bolts 141-191 ft.lb Front Brake Hose-to-Caliper Flow Bolt 23-29 ft.lb Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Bleeding Brake Caliper: Service and Repair Bleeding 1. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. Repeat until clear bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Bleeding > Page 6272 Brake Caliper: Service and Repair Front Anchor Plate Removal 1. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1. Remove the two front disc brake caliper anchor plate bolts. 2. Remove the front disc brake caliper anchor plate. Installation 1. Install the front disc brake caliper anchor plate. 1. Position the front disc brake caliper anchor plate. 2. Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Disassembly and Assembly DISASSEMBLY 1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper 3. Secure the disc brake caliper in a vise. 4. Remove the caliper pistons. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper. 3 Force out the caliper pistons to the block of wood. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Bleeding > Page 6273 4 Remove the block of wood and the caliper piston. 5. Remove and discard the piston seals and boots. 6. If the disc brake caliper is leaking, replace the piston seals. If the caliper bores are excessively scored or corroded, replace the disc brake caliper. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores. ASSEMBLY 1. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. CAUTION: Never reuse piston seals or dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. 2. Install the caliper pistons. 1 Install the piston seal. 2 Install the piston boot. 3 Insert the caliper piston. CAUTION: Be careful not to damage or dislodge the piston seal. 4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston. 3. Install the disc brake caliper. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Bleeding > Page 6274 Removal and Installation REMOVAL WARNING: - BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. - ASBESTOS FIBER DUST CAN BE PRESENT ON BRAKE AND CLUTCH ASSEMBLIES AND IS HAZARDOUS TO HEALTH IF INHALED. - BRAKE AND CLUTCH ASSEMBLIES MUST BE CLEANED USING A VAC WM CLEANER RECOMMENDED FOR USE WITH ASBESTOS FIBERS, SUCH AS A BRAKE/CLUTCH/SERVICE VACUUM. THE BAG MUST BE LABELED IN ACCORDANCE WITH OSHA INSTRUCTIONS, SEALED, AND THE TRASH HAULER NOTIFIED AS TO THE BAG'S CONTENTS. - IF A VACUUM SUITABLE FOR ASBESTOS IS NOT AVAILABLE, CLEANING MUST BE DONE WET. IF DUST GENERATION IS STILL POSSIBLE, TECHNICIANS MUST WEAR GOVERNMENT-APPROVED TOXIC DUST PURIFYING RESPIRATORS. - THE OCCUPATIONAL HEALTH AND SAFETY ACT (OSHA) REQUIRES AREAS WHERE ASBESTOS DUST GENERATION IS POSSIBLE TO BE ISOLATED AND POSTED WITH WARNING SIGNS. ONLY TECHNICIANS PERFORMING BRAKE OR CLUTCH REPAIR ARE TO BE PRESENT IN THE AREA. 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. If so equipped, unclip the speed sensor wiring from the front brake hose. 4. Disconnect the front brake hose from the disc brake caliper. 1 Remove the flow bolt. 2 Disconnect the front brake hose. 3 Remove and discard the copper washers. CAUTION: To prevent contamination and reduce air entry, always plug a disconnected front brake hose. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Bleeding > Page 6275 5. Remove the two disc brake caliper bolts. 6. Remove the disc brake caliper from the front disc brake caliper anchor plate. 7. Inspect the disc brake caliper for brake fluid leakage. If the disc brake caliper is leaking, it must be rebuilt or replaced. INSTALLATION 1. Fill the rubber caliper sleeve boots with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. CAUTION: To prevent deterioration of the caliper sleeve boots, do not use petroleum-based lubricant. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Bleeding > Page 6276 2. Install the disc brake caliper and the front brake hose. 1 Position the disc brake caliper in the front disc brake caliper anchor plate. 2 Install and tighten the disc brake caliper bolts. 3 Using new copper washers, install the front brake hose and the bolt. 3. If so equipped, attach the speed sensor wiring to the front brake hose. 4. Bleed the brake system. 5. Install the wheel and tire assembly. 6. Inspect the brake system operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing Brake Fluid: Customer Interest Steering/Brakes - Brake Pedal Kick-Back/Grabbing TSB 07-11-10 06/11/07 BRAKE PEDAL KICKBACK OR GRABBING FORD: 1997-2007 E-Series 1999-2008 F-Super Duty 2000-2005 Excursion This article supersedes TSB 99-25-8 to update the vehicle model years. ISSUE Some 1999-2008 F-Super Duty, 2000-2005 Excursion, and 1997-2007 E-Series vehicles equipped with Hyrdo-Boost(R) brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes. This may be caused by contamination within the power steering system. ACTION Filter the power steering fluid by installing a temporary filter in the power steering system. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Verify that the line from the pump and the line to the gear at the Hydro-Boost(R) are in their correct orientation (and not crossed). The passenger side goes to the pump, the driver side goes to the gear. 2. Attach a pinch-off clamp to the lower power steering hose approximately 6" (15 cm) from the lower port of the power steering cooler to keep fluid from emptying out of the system when the hose is disconnected. 3. Disconnect the power steering hose from the lower port on the cooler. Cap the cooler port to minimize fluid leakage and immediately install the temporary filter in line with the power steering hose using hose clamps to retain the filter (the filter needs to go in the low pressure line that goes from gear to cooler to reservoir, where it would be most accessible). 4. Attach the other end of the filter to the cooler using the clamps provided. 5. Remove the pinch-off clamp from the power steering hose. FILTERING PROCEDURE CAUTION BE SURE THAT THE PARKING BRAKE IS APPLIED DURING THE FOLLOWING STEPS 1-7. 1. Check power steering fluid level before starting the vehicle. 2. Start the vehicle and allow it to idle for approximately 15 seconds. NOTE DO NOT HOLD THE STEERING AT LOCK FOR MORE THAN 5 SECONDS. 3. Turn steering wheel lock-to-lock 10 times. 4. Pump service brake pedal hard to floor 25 times. 5. Turn steering wheel lock-to-lock 5 times. 6. Remove the filter and reconnect the power steering line to the cooler. Discard the filter. Fill the power steering system. Refer to Workshop Manual (WSM), Section 211-00 Power Steering System Filling. 7. With the engine at idle, gradually apply the brake pedal until fully applied. If the brake pedal kickback persists, replace the Hydro-Boost(R) brake booster. Refer to WSM, Section 206-07. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing > Page 6285 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 MTO71110 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 2005 07 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing Brake Fluid: All Technical Service Bulletins Steering/Brakes - Brake Pedal Kick-Back/Grabbing TSB 07-11-10 06/11/07 BRAKE PEDAL KICKBACK OR GRABBING FORD: 1997-2007 E-Series 1999-2008 F-Super Duty 2000-2005 Excursion This article supersedes TSB 99-25-8 to update the vehicle model years. ISSUE Some 1999-2008 F-Super Duty, 2000-2005 Excursion, and 1997-2007 E-Series vehicles equipped with Hyrdo-Boost(R) brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes. This may be caused by contamination within the power steering system. ACTION Filter the power steering fluid by installing a temporary filter in the power steering system. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Verify that the line from the pump and the line to the gear at the Hydro-Boost(R) are in their correct orientation (and not crossed). The passenger side goes to the pump, the driver side goes to the gear. 2. Attach a pinch-off clamp to the lower power steering hose approximately 6" (15 cm) from the lower port of the power steering cooler to keep fluid from emptying out of the system when the hose is disconnected. 3. Disconnect the power steering hose from the lower port on the cooler. Cap the cooler port to minimize fluid leakage and immediately install the temporary filter in line with the power steering hose using hose clamps to retain the filter (the filter needs to go in the low pressure line that goes from gear to cooler to reservoir, where it would be most accessible). 4. Attach the other end of the filter to the cooler using the clamps provided. 5. Remove the pinch-off clamp from the power steering hose. FILTERING PROCEDURE CAUTION BE SURE THAT THE PARKING BRAKE IS APPLIED DURING THE FOLLOWING STEPS 1-7. 1. Check power steering fluid level before starting the vehicle. 2. Start the vehicle and allow it to idle for approximately 15 seconds. NOTE DO NOT HOLD THE STEERING AT LOCK FOR MORE THAN 5 SECONDS. 3. Turn steering wheel lock-to-lock 10 times. 4. Pump service brake pedal hard to floor 25 times. 5. Turn steering wheel lock-to-lock 5 times. 6. Remove the filter and reconnect the power steering line to the cooler. Discard the filter. Fill the power steering system. Refer to Workshop Manual (WSM), Section 211-00 Power Steering System Filling. 7. With the engine at idle, gradually apply the brake pedal until fully applied. If the brake pedal kickback persists, replace the Hydro-Boost(R) brake booster. Refer to WSM, Section 206-07. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing > Page 6291 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 MTO71110 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 2005 07 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Fluid: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Fluid: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6297 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Fluid: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6298 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Fluid: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6304 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Fluid: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6305 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 6306 Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. High Performance DOT3 Brake Fluid Ford Specification ESA-M6C25-A Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service Precautions > Technician Safety Information Brake Fluid: Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service Precautions > Technician Safety Information > Page 6309 Brake Fluid: Vehicle Damage Warnings Clean, fresh Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A is the only brake fluid that should be used in Ford vehicles. - Do not reuse brake fluid drained or bled from the system. - Do not use brake fluid that has been stored in an open container. - Do not use contaminated brake fluid. - Do not mix different types of brake fluid. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Fluid Level Sensor/Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6314 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6315 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6316 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6317 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6318 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6319 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6320 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 6321 Brake Fluid Level Sensor/Switch: Description and Operation The Brake Fluid Level Sensor is incorporated into the Dual Brake Warning Switch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose Brake Hose/Line: Specifications Brake Hose TORQUE SPECIFICATIONS Front Brake Hose Bolt ......................................................................................................................... ...................................... 30-40 Nm (22-30 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose > Page 6326 Brake Hose/Line: Specifications Brake Line TORQUE SPECIFICATIONS Brake Master Cylinder Tube Fitting, Front ................................................................................................................................ 22-28 Nm (17-20 ft. lbs.) Brake Master Cylinder Tube Fitting, Rear ................................................................................................................................. 15-20 Nm (11-14 ft. lbs.) Brake Line-to-Rear Wheel Cylinder Fitting ............................................................................................................................... 15-20 Nm (11-14 ft. lbs.) Brake Master Cylinder To Rear Anti-Lock Brake Sensor Valve Hydraulic Line ............................................................................................................................................... 15-20 Nm (11-14 ft. lbs.) Rear Anti-Lock Brake Sensor Valve To Rear Axle Brake Junction Block Hydraulic Line .................................................................................................................................. 15-20 Nm (11-14 ft. lbs.) 1/2-20 Brake Line ................................................................................................................................ ...................................... 21-29 Nm (16-21 ft. lbs.) 7/16-24 Brake Line ............................................... ..................................................................................................................... 15-20 Nm (11-14 ft. lbs.) Brake Line To Brake Master Cylinder ....................................................................................................................................... 15-20 Nm (11-14 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Brake Hose Brake Hose/Line: Description and Operation Brake Hose CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which could result in brake tube failure. Double wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be properly double flared to provide strong leakproof connections. When bending tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube. If a section of brake tube is damaged, the entire section must be replaced with a tube of the same type, size, shape and length. When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After replacement, bleed the brake system. The wet appearance on the outer cover of rubber brake hoses is called ''sweating." This is a normal condition for neoprene rayon braid hose and is not a sign of leakage or cause for replacement of the hose. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Brake Hose > Page 6329 Brake Hose/Line: Description and Operation Brake Line CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which could result in brake tube failure. Double wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be properly double flared to provide strong leakproof connections. When bending tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube. If a section of brake tube is damaged, the entire section must be replaced with a tube of the same type, size, shape and length. When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After replacement, bleed the brake system. The wet appearance on the outer cover of rubber brake hoses is called ''sweating." This is a normal condition for neoprene rayon braid hose and is not a sign of leakage or cause for replacement of the hose. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications Brake Proportioning/Combination Valve: Specifications TORQUE SPECIFICATIONS Brake Load Sensor Proportioning Valve Flow Bolt .............................................................................................................................................. ............................... 23-34 Nm (17-25 ft. lbs.) Shaft Nut ...................................................................... ........................................................................................................ 15-20 Nm (12-14 ft. lbs.) Linkage-to-Differential Housing Nuts .................................................................................................................................. 15-19 Nm (12-14 ft. lbs.) Mounting Bolts .............................................................................................................. ...................................................... 30-40 Nm (23-29 ft. lbs.) Mounting Bracket-to-Frame Bolts ....................................................................................................................................... 32-48 Nm (24-35 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 6333 Brake Proportioning/Combination Valve: Description and Operation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 6334 Brake Proportioning/Combination Valve: Adjustments Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 6335 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 6336 Brake Proportioning/Combination Valve: Service and Repair Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 6337 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Hydraulic Assembly Hydraulic Control Assembly - Antilock Brakes: Specifications Hydraulic Assembly TORQUE SPECIFICATIONS Hydraulic Control Unit Bracket To Inner Fender Well Nuts ................................................................................................................................. ................................ 24-31 Nm (18-23 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Hydraulic Assembly > Page 6342 Hydraulic Control Assembly - Antilock Brakes: Specifications Solenoid Valve Body TORQUE SPECIFICATIONS Rear Antilock Brake Valve Nuts ................................................................................................................................................ 21-29 Nm (15-21 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Assembly Bleeding NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been replaced or if the HCU lines have been opened. 1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 2. Connect a clear waste line to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 3. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 6345 4. Tighten the RH rear bleeder screw, and disconnect the waste line. 5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw, in that order. 6. Connect the NGS DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the NGS instructions. 7. Repeat the system bleed procedure as outlined in Steps 1 through 5. Replacement REMOVAL WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. 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. Disconnect the battery ground cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 6346 2. Position the radiator coolant recovery reservoir aside. 1 Remove the bolts. 2 Position the radiator coolant recovery reservoir aside. 3. Remove the bolts and position the power steering pump reservoir aside. NOTE: Do not disconnect the hose from the power steering pump reservoir. 4. Disconnect the brake lines from the brake master cylinder. 5. Disconnect the brake lines. 1 Remove the 7/16-24 brake lines. 2 Disconnect the 1/2-20 brake lines. NOTE: Plug each port of the electronic hydraulic control unit (EHCU) to prevent brake fluid from spilling. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 6347 6. Disconnect the anti-lock brake control module electrical connector. 1 Lift the lock tab upward. 2 Disconnect the anti-lock brake control module electrical connector. 7. Remove the EHCU bracket to inner fender well nuts. 8. Remove the EHCU. 1 Disconnect the anti-lock brake control module electrical connectors. 2 Remove the EHCU. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 6348 1. To install, reverse the removal procedure. 2. Bleed the EHCU after installation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 6349 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Solenoid Valve Body REMOVAL 1. Remove the RABS valve. 1 Disconnect the electrical connector 2 Remove the hydraulic lines and plug them. 3 Remove the nuts. 4 Remove the RABS valve. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. INSTALLATION RABS Valve Installation 1. To install, reverse the removal procedure. - Bleed the brakes. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6350 Bleeding Components Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications TORQUE SPECIFICATIONS Master Cylinder-to-Vacuum Booster Nut .................................................................................................................................. 21-28 Nm (16-20 ft. lbs.) Master Cylinder Fluid Control Valve ......................................................................................................................................... 21-29 Nm (16-21 ft. lbs.) Master Cylinder to RABS Sensor Valve Hydraulic Line [1] ..................................................................................................... 15-20 Nm (11-14 ft. lbs.) [1] RABS - Rear Antilock Brake System Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Fluid Reservoir Brake Master Cylinder: Description and Operation Brake Fluid Reservoir The brake master cylinder reservoir is equipped with a fluid level sensor to detect low brake fluid level. The fluid level sensor will provide a ground path to light the brake warning lamp. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Fluid Reservoir > Page 6356 Brake Master Cylinder: Description and Operation Master Cylinder, Brakes The brake master cylinder: - has a brake master cylinder fluid control valve, mounted in the rear outlet port (except dual rear wheel and 9600 GVW E-350 vehicles), to limit hydraulic pressure to the rear brakes during normal braking. - on speed control-equipped vehicles, has a speed control deactivator switch mounted at the front end to act as a redundant safety device. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Compensator Port Test Brake Master Cylinder: Testing and Inspection Compensator Port Test The purpose of the compensator ports in the brake master cylinder is to supply any additional brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the brake lines to the brake master cylinder to enter the brake roaster cylinder reservoir. The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir. Turbulence seen in the brake master cylinder reservoir upon release of the brake pedal is normal and shows that the compensating ports are not plugged. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Compensator Port Test > Page 6359 Brake Master Cylinder: Testing and Inspection Functional Test 1. Disconnect the brake lines at the brake master cylinder. 2. Plug the outlet ports of the brake master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and must be rebuilt or replaced. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir Brake Master Cylinder: Service and Repair Brake Fluid Reservoir REMOVAL WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. 1. Disconnect the brake master cylinder fluid level warning switch. 2. Use a suitable suction device to drain the brake master cylinder reservoir. 3. Carefully pry up on the brake master cylinder reservoir to remove. INSTALLATION 1. Install the brake master cylinder reservoir. 1 Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. and insert the grommets in the brake master cylinder. 2 Press the brake master cylinder reservoir into the grommets until it snaps. 3 Connect the brake master cylinder fluid level warning switch. 4 Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. NOTE: Whenever replacing the brake master cylinder reservoir, replace the grommets. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6362 Brake Master Cylinder: Service and Repair Master Cylinder, Brakes Disassembly and Assembly DISASSEMBLY WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. 1. Remove the brake master cylinder. 2. Clean the outside of the brake master cylinder. 3. Remove the brake master cylinder filler cap and drain the remaining brake fluid. 4. If equipped, remove the brake pressure switch. 5. Remove the brake master cylinder fluid control valve. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6363 6. Remove the primary piston assembly. 1 Depress the primary piston and remove the snap ring. 2 Remove and discard the primary piston assembly. 7. Remove the secondary piston assembly. 1 Plug the rear outlet port and, if necessary, plug the brake pressure switch port. 2 Apply compressed air into the front outlet port and remove the secondary piston assembly and discard. 8. Use isopropyl alcohol to clean and inspect the brake master cylinder bore for damage. NOTE: If the brake master cylinder bore is damaged, the brake master cylinder must be replaced. ASSEMBLY WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. 1. Use clean High-Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A to lubricate the new piston assembly seals. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6364 2. Carefully install the secondary piston assembly. 3. Carefully install the primary piston assembly. 4. Install the snap ring. 1 Depress the primary piston. 2 Install the snap ring. 5. Install the brake master cylinder fluid control valve. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6365 6. If equipped, install the brake pressure switch. 7. Install the brake master cylinder. 8. Fill the brake master cylinder reservoir with High-Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A and install the brake master cylinder filler cap . 9. Bleed the brake master cylinder. Master Cylinder Priming - In Vehicle or Bench WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: - Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. - 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 any part of the hydraulic system has been disconnected for repair or replacement, air can enter the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. - When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6366 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir, and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 4. Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 5. If the brake master cylinder is being primed at the bench, install it in the vehicle. 6. Remove the short brake tubes, and install the brake outlet tubes. 7. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal. 2 Loosen the rearmost brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten 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 at the front brake tube. Removal and Installation REMOVAL WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. 1. Disconnect the battery ground cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6367 2. Remove the three power distribution box bracket bolts and position the box aside. 3. Disconnect the brake fluid level warning switch. 4. If equipped with speed control, disconnect the brake pressure switch electrical connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6368 5. Disconnect the two brake lines and plug the lines and the brake master cylinder ports. 6. Remove the brake master cylinder. 1 Remove the two brake master cylinder nuts. 2 Remove the brake master cylinder. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6369 1. Follow the removal procedure in reverse order. - Bleed the brake system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Bleeder Screw 62-79 in.lb Rear Wheel Cylinder Bolts 9-13 ft.lb Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation Wheel Cylinder: Service and Repair Removal and Installation REMOVAL 1. Remove the brake shoes and linings. 2. Remove the rear wheel cylinder. 1 Disconnect the brake line fitting. 2 Remove the two rear wheel cylinder bolts. 3 Remove the rear wheel cylinder. INSTALLATION 1. Follow the removal procedure in reverse order. 2. Bleed the brake system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 6375 Wheel Cylinder: Service and Repair Disassembly And Assembly DISASSEMBLY 1. Disassemble the rear wheel cylinder. 1 Remove the rubber boots. 2 Remove the rear wheel cylinder pistons 3 Remove the cups. 4 Remove the expander. 5 Remove the wheel cylinder bleeder screw from the rear wheel cylinder. NOTE: Removal is not necessary to disassemble. inspect, hone or overhaul the rear wheel cylinder. ASSEMBLY 1. Follow the disassembly procedure in reverse order NOTE: Coat all the rear wheel cylinder parts with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments Parking Brake Cable: Adjustments 1. Loosen the tension limiter nut to the end of the tension limiter threads. 2. Depress the parking brake pedal to the last detent position. NOTE: The last detent is 17 clicks. 3. Measure and record the exposed length of the cinch strap. 4. Tighten the tension limiter nut to 7.6-8.3 cm (3-3.25 inches) from the end of the tension limiter threads. Measure from the end of the tension limiter threads to the beginning of the hex portion of the tension limiter nut. NOTE: Prevent the tension limiter from turning while tightening. 5. Make sure the tightening has caused the cinch strap to slip the minimum specified length from the length recorded in Step 3. If the cinch strap has Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Page 6380 not slipped the specified amount, tighten the tension limiter nut the additional amount necessary to achieve the specified slippage. NOTE: The tension limiter will reset the parking brake tension any time the system is disconnected, provided the distance between the bracket and the cinch strap hook is reduced during adjustment. When the cinch strap hook contacts the bracket, the tension limiter must be replaced to prevent overtensioning. 6. Release the parking brake control. 7. Depress to the floor and release the parking brake control two times. 8. Test the parking brake. 1 Apply the parking brake. The parking brake cables must be tight enough to provide full application of the rear brake shoes and linings. 2 Release the parking brake. The parking cables must be loose enough so that there is no drag at the rear wheels. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications Parking Brake Control: Specifications TORQUE SPECIFICATIONS Parking Brake Control Nuts ....................................................................................................................................................... 17-23 Nm (13-17 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6384 Parking Brake Control: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Disconnect the front parking brake cable and conduit. 1 Remove the tension limiter nut. 2 Separate the tension limiter from the equalizer. 3. Lower the vehicle. 4. Remove the LH cowl side trim panel. 5. Disconnect the electrical connector from the parking brake signal switch and bracket. 6. Remove three parking brake control nuts and separate the parking brake control from the steering column support bracket. 7. Remove the cable end retainer from the parking brake control. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6385 8. Remove the front parking brake cable and conduit. 1 Using box wrench, compress the fingers of the parking brake cable retainer. 2 Pull the front parking brake cable and conduit from the parking brake control. INSTALLATION 1. Follow the removal procedure in reverse order. 2. Adjust the cable tension. 3. Test parking brake function. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Brake Booster: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing Hydraulic Brake Booster: Customer Interest Steering/Brakes - Brake Pedal Kick-Back/Grabbing TSB 07-11-10 06/11/07 BRAKE PEDAL KICKBACK OR GRABBING FORD: 1997-2007 E-Series 1999-2008 F-Super Duty 2000-2005 Excursion This article supersedes TSB 99-25-8 to update the vehicle model years. ISSUE Some 1999-2008 F-Super Duty, 2000-2005 Excursion, and 1997-2007 E-Series vehicles equipped with Hyrdo-Boost(R) brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes. This may be caused by contamination within the power steering system. ACTION Filter the power steering fluid by installing a temporary filter in the power steering system. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Verify that the line from the pump and the line to the gear at the Hydro-Boost(R) are in their correct orientation (and not crossed). The passenger side goes to the pump, the driver side goes to the gear. 2. Attach a pinch-off clamp to the lower power steering hose approximately 6" (15 cm) from the lower port of the power steering cooler to keep fluid from emptying out of the system when the hose is disconnected. 3. Disconnect the power steering hose from the lower port on the cooler. Cap the cooler port to minimize fluid leakage and immediately install the temporary filter in line with the power steering hose using hose clamps to retain the filter (the filter needs to go in the low pressure line that goes from gear to cooler to reservoir, where it would be most accessible). 4. Attach the other end of the filter to the cooler using the clamps provided. 5. Remove the pinch-off clamp from the power steering hose. FILTERING PROCEDURE CAUTION BE SURE THAT THE PARKING BRAKE IS APPLIED DURING THE FOLLOWING STEPS 1-7. 1. Check power steering fluid level before starting the vehicle. 2. Start the vehicle and allow it to idle for approximately 15 seconds. NOTE DO NOT HOLD THE STEERING AT LOCK FOR MORE THAN 5 SECONDS. 3. Turn steering wheel lock-to-lock 10 times. 4. Pump service brake pedal hard to floor 25 times. 5. Turn steering wheel lock-to-lock 5 times. 6. Remove the filter and reconnect the power steering line to the cooler. Discard the filter. Fill the power steering system. Refer to Workshop Manual (WSM), Section 211-00 Power Steering System Filling. 7. With the engine at idle, gradually apply the brake pedal until fully applied. If the brake pedal kickback persists, replace the Hydro-Boost(R) brake booster. Refer to WSM, Section 206-07. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Brake Booster: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing > Page 6395 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 MTO71110 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 2005 07 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing Hydraulic Brake Booster: All Technical Service Bulletins Steering/Brakes - Brake Pedal Kick-Back/Grabbing TSB 07-11-10 06/11/07 BRAKE PEDAL KICKBACK OR GRABBING FORD: 1997-2007 E-Series 1999-2008 F-Super Duty 2000-2005 Excursion This article supersedes TSB 99-25-8 to update the vehicle model years. ISSUE Some 1999-2008 F-Super Duty, 2000-2005 Excursion, and 1997-2007 E-Series vehicles equipped with Hyrdo-Boost(R) brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes. This may be caused by contamination within the power steering system. ACTION Filter the power steering fluid by installing a temporary filter in the power steering system. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Verify that the line from the pump and the line to the gear at the Hydro-Boost(R) are in their correct orientation (and not crossed). The passenger side goes to the pump, the driver side goes to the gear. 2. Attach a pinch-off clamp to the lower power steering hose approximately 6" (15 cm) from the lower port of the power steering cooler to keep fluid from emptying out of the system when the hose is disconnected. 3. Disconnect the power steering hose from the lower port on the cooler. Cap the cooler port to minimize fluid leakage and immediately install the temporary filter in line with the power steering hose using hose clamps to retain the filter (the filter needs to go in the low pressure line that goes from gear to cooler to reservoir, where it would be most accessible). 4. Attach the other end of the filter to the cooler using the clamps provided. 5. Remove the pinch-off clamp from the power steering hose. FILTERING PROCEDURE CAUTION BE SURE THAT THE PARKING BRAKE IS APPLIED DURING THE FOLLOWING STEPS 1-7. 1. Check power steering fluid level before starting the vehicle. 2. Start the vehicle and allow it to idle for approximately 15 seconds. NOTE DO NOT HOLD THE STEERING AT LOCK FOR MORE THAN 5 SECONDS. 3. Turn steering wheel lock-to-lock 10 times. 4. Pump service brake pedal hard to floor 25 times. 5. Turn steering wheel lock-to-lock 5 times. 6. Remove the filter and reconnect the power steering line to the cooler. Discard the filter. Fill the power steering system. Refer to Workshop Manual (WSM), Section 211-00 Power Steering System Filling. 7. With the engine at idle, gradually apply the brake pedal until fully applied. If the brake pedal kickback persists, replace the Hydro-Boost(R) brake booster. Refer to WSM, Section 206-07. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing > Page 6401 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 MTO71110 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 2005 07 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications TORQUE SPECIFICATIONS Vacuum Booster-to-Dash Panel And Pedal Support Nut ............................................................................................................................... ................................. 26-34 Nm (20-25 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6405 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6406 Vacuum Brake Booster: Description and Operation The power brake booster: - is a dual diaphragm. vacuum assisted power brake booster. - reduces brake pedal pressure and travel distance. - is located on the LH side of the bulkhead in the engine compartment, between the brake pedal and brake master cylinder. - is divided into separate chambers by the diaphragm - will not operate if vacuum is restricted or if any of the vacuum related power brake components fail. - is replaced as an assembly. If the power assist fails, the brake system will continue to operate with increased brake pedal effort. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6407 Vacuum Brake Booster: Testing and Inspection 1. With the transmission in NEUTRAL and the engine stopped, apply the brakes several times to exhaust the vacuum in the vacuum boost system. 2. Hold the brake pedal in the applied position. 3. Start the engine. 4. If the power brake system is functioning properly, the brake pedal can be felt to move downward after the engine starts. 5. With a vacuum type power brake booster, if engine vacuum is available to the power brake booster and no power assist is felt, replace the power brake booster and retest the system Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6408 Vacuum Brake Booster: Service and Repair REMOVAL 1. Remove the brake master cylinder. 2. Disconnect the power brake booster hose. 1 Compress the clamp. 2 Disconnect the power brake booster hose 3. Disconnect the brake pedal to power brake booster push rod. 1 Remove the self-locking pin. 2 Remove the brake master cylinder push rod spacers. 3 Remove the stoplight switch from the brake master cylinder push rod. 4 Remove the brake master cylinder push rod bushing. 4. Remove the bulkhead sound insulator. 5. Remove the power brake booster. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6409 1 Remove the nuts. 2 Remove the power brake booster INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Locations > Page 6413 Vacuum Brake Booster Check Valve: Description and Operation The power brake booster check valve: - is located on the front of the power brake booster. - check valve and grommet can be replaced separately. - is positioned between the power brake booster and the power brake booster hose. - closes when the engine is turned off. - in the closed position, traps engine vacuum in the power brake booster. - retains vacuum to provide several power assisted brake applications with the engine off. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Locations > Page 6414 Vacuum Brake Booster Check Valve: Testing and Inspection The function of the power brake booster check valve is to allow manifold vacuum to enter the power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full throttle operation. To test the function of the power brake booster check valve: - Start and run the engine for at least 10 seconds. - Operate the brake pedal to check for power assist. - Disconnect the vacuum booster hose from the power brake booster. Do not remove the power brake booster check valve from the power brake booster. - There should be enough vacuum retained in the power brake booster for at least one more power-assisted brake operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Instrument Panel Views The 4 Wheel Anti-Lock Brakes Relay is located behind the center of instrument panel, on 4 wheel anti-lock brakes relay. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 6419 4 Wheel Anti_Lock Brake System Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Rear Anti-Lock Brakes Electronic Brake Control Module: Specifications Rear Anti-Lock Brakes TORQUE SPECIFICATIONS Anti-Lock Brake Control Module Screws .................................................................................................................................. 2-3 Nm (17-26 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Rear Anti-Lock Brakes > Page 6424 Electronic Brake Control Module: Specifications 4-Wheel Anti-Lock Brakes TORQUE SPECIFICATIONS Anti-Lock Brake Control Module Screws ................................................................................................................................................. .................................. 4-5 Nm (36-44 inch lbs.) To Bracket Bolts ........................................................ .......................................................................................................... 30-40 Nm (22-29 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Rear Antilock Brake (RABS) Module Electronic Brake Control Module: Locations Rear Antilock Brake (RABS) Module Instrument Panel Views The Rear Anti-Lock Brake System Module is located behind center side of the instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Rear Antilock Brake (RABS) Module > Page 6427 Electronic Brake Control Module: Locations 4 Wheel Anti-Lock Brake System Module Engine Compartment Views The 4 Wheel Anti-Lock Brakes Module is located on the LH front frame rail. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Four Wheel Antilock Brakes 4 Wheel Anti_Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Four Wheel Antilock Brakes > Page 6430 Rear Anti_Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) Electronic Brake Control Module: Service and Repair Four Wheel Anti-Lock Brake System (4WABS) REMOVAL 1. Remove the electronic hydraulic control unit (EHCU). 2. Detach the bracket from the EHCU. 1 Remove the bolts. 2 Detach the bracket from the EHCU. 3. Remove the anti-lock brake control module. 1 Remove the screws. 2 Remove the anti-lock brake control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6433 Electronic Brake Control Module: Service and Repair Rear Antilock Brake System (RABS) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the engine cover. 3. Remove the anti-lock brake control module. 1 Remove the screw. 2 Lower the module assembly. 3 Remove the nuts. 4 Disconnect the electrical connector. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6434 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to driven 16 km ( 10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Fluid Level Sensor/Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6440 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6441 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6442 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6443 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6444 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6445 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6446 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 6447 Brake Fluid Level Sensor/Switch: Description and Operation The Brake Fluid Level Sensor is incorporated into the Dual Brake Warning Switch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Rear Anti-Lock Brakes Wheel Speed Sensor: Specifications Rear Anti-Lock Brake Sensor Pole Piece To Rear Anti-Lock Brake Sensor Indicator Clearance 0.005-0.045 in Rear Anti-Lock Brake Sensor Bolt 25-29 ft.lb Rear Anti-Lock Brake Sensor Nuts 15-21 ft.lb Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Rear Anti-Lock Brakes > Page 6452 Wheel Speed Sensor: Specifications Front Anti-Lock Brake Sensor Bolt 62-80 in.lb Front Anti-Lock Brake Sensor Wire Retaining Bolt 7-9 ft.lb Rear Anti-Lock Sensor Bolt 25-29 ft.lb Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Rear Axle Speed Sensor Wheel Speed Sensor: Locations Rear Axle Speed Sensor Full Body Views The Rear Axle Speed Sensor is located below the rear of vehicle, mounted on differential. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Rear Axle Speed Sensor > Page 6455 Wheel Speed Sensor: Locations Wheel Speed Sensor Left Front Full Body Views The Left Front Wheel Sensor is located behind LH front wheel. Right Front Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Rear Axle Speed Sensor > Page 6456 Full Body Views The Right Front Wheel Sensor is located near right front wheel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring Wheel Speed Sensor: Service and Repair Toothed Ring Front REMOVAL 1. Remove the front disc brake rotor. 2. Use 2-3 Jaw Puller to remove the front anti-lock brake sensor indicator. CAUTION: Discard the front anti-lock brake sensor indicator. INSTALLATION 1. Use an appropriate size cylinder and press to install the front anti-lock brake sensor indicator. CAUTION: The front anti-lock brake sensor indicator must be pressed on straight. 2. Install the front disc brake rotor. Rear For removal and installation of the rear brake anti-lock sensor indicator, refer to Differential. NOTE: The rear anti-lock brake sensor indicator is attached to the ring gear. It is necessary to remove the ring gear in order to remove the rear anti-lock brake sensor indicator. Rear Antilock Brake System (RABS) For removal and installation of the rear brake anti-lock sensor indicator, refer to Differential. NOTE: The rear anti-lock brake sensor indicator is attached to the ring gear. It is necessary to remove the ring gear in order to remove the rear anti-lock brake sensor indicator. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 6459 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Rear Antilock Brake System REMOVAL 1. Raise and support the vehicle. 2. Remove the rear anti-lock brake sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. CAUTION: Do not get dirt in the rear axle housing. INSTALLATION 1. Clean and inspect the rear anti-lock brake sensor. 1 Clean the rear axle housing mounting surface. 2 Inspect and clean the magnetized sensor pole piece. 3 Inspect the sensor and O-ring for damage. Replace if necessary. 4 Lightly lubricate the O-ring with motor oil. CAUTION: Do not get dirt in the rear axle housing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 6460 2. Measure the clearance between the rear anti-lock brake sensor pole piece and the rear anti-lock brake sensor indicator. 3. Install the rear anti-lock brake sensor. 1 Position the sensor and install the bolt. NOTE: Do not apply force to the plastic rear anti-lock brake sensor connector. The rear anti-lock brake sensor flange should slide to the mounting surface. 2 Connect the electrical connector. Front REMOVAL 1. Remove the front disc brake rotor. 2. Detach the front anti-lock brake sensor wire from the front brake hose. 1 Disconnect the front anti-lock brake sensor electrical connector. 2 Detach the front anti-lock brake sensor wire from the front brake hose. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 6461 3. Remove the bolt. 4. Remove the front anti-lock brake sensor. 1 Remove the front anti-lock brake sensor bolts. 2 Remove the front anti-lock brake sensor. INSTALLATION 1. To install, reverse the removal procedure. Rear REMOVAL 1. Raise and support vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 6462 2. Remove the rear anti-lock brake sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. INSTALLATION CAUTION: Use care not to get dirt in the rear axle housing. 1. Clean and inspect the rear anti-lock brake sensor. 1 Clean the axle mounting surface. 2 Inspect and clean the rear anti-lock brake sensor. 3 Inspect the rear anti-lock brake sensor O-ring for damage. Replace if necessary. 4 Lightly lubricate the rear anti-lock brake sensor O-ring with Synthetic SAE 75W 140 Rear Axle Lubricant F1TZ-19580-A or equivalent meeting Ford specification WSL-M2C192-A. 2. Install the rear anti-lock brake sensor. 1 Position the rear anti-lock brake sensor and install the bolt. 2 Connect the electrical connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 6463 CAUTION: Do not apply force to the plastic rear anti-lock brake sensor connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Page 6464 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6472 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6473 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6474 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6475 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6476 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 6477 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Replacement, Functional Ignition Switch Lock Cylinder: Service and Repair Replacement, Functional REMOVAL NOTE: The following procedure applies to vehicles that have functional lock cylinders and keys. If key numbers are known, the proper key can be made. 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Position the lock cylinder to RUN. (2) Using a suitable tool, push upward on the cylinder release tab through the hole in the lower shroud while pulling the cylinder outward. INSTALLATION 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Replacement, Functional > Page 6480 Ignition Switch Lock Cylinder: Service and Repair Replacement, Non-Functional REMOVAL NOTE: The following procedure applies to vehicles in which the ignition lock is inoperative and the lock cylinder cannot be rotated due to a lost or broken key, unknown key number, or a cap that has been damaged or broken to the extent that the lock cylinder cannot be rotated. 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 1/8 inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8 inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Replacement, Functional > Page 6481 6. Remove the bearing and the gear. - Thoroughly clean all drill shavings from the steering column and inspect it for damage. INSTALLATION 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. NOTE: Use a new ignition switch lock cylinder. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 6485 Neutral Safety Switch: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 6486 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications Starter Relay: Specifications Starter Motor Solenoid Relay Switch Mounting Bolts ........................................................................................................................ 7-9 N.m (61-79 Lb/In) Starter Motor Relay Mounting Screws ................................................................................................................................................ 7-9 N.m (62-80 Lb/In) Starter Motor Relay B+ and Enable terminal Nuts .............................................................................................................................. 7-9 N.m (62-80 Lb/In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 6491 Starter Relay: Locations The Starter Motor Relay is located at the RH front corner of the engine compartment, near battery. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 6492 Starter Relay: Description and Operation The starter motor solenoid relay switch: - controls current to the starter solenoid. - is engaged by the ignition switch. - connects the battery to the starter motor. The Transimission Range (TR) sensor on automatic transmission-equipped vehicles prevents starter motor engagement unless the transmission is in the NEUTRAL or PARK position Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 6493 Starter Relay: Service and Repair REMOVAL WARNING: WHEN REPAIRING THE STARTER MOTOR OR PERFORMING OTHER UNDERHOOD WORK IN THE VICINITY OF THE STARTER MOTOR, BE AWARE THAT THE HEAVY GAUGE BATTERY INPUT LEAD AT THE STARTER SOLENOID IS ELECTRICALLY HOT AT ALL TIMES. THE PROTECTIVE CAP OR BOOT PROVIDED OVER THIS TERMINAL MUST BE REPLACED AFTER MAINTENANCE IS COMPLETE. MAKE SURE TO DISCONNECT THE BATTERY GROUND CABLE BEFORE WORKING ON THE STARTER MOTOR. 1. Disconnect the battery ground cable. 2. Remove the relay cover. 3. Disconnect the starter motor solenoid relay switch wires and cables. 1. Remove the insulator. 2. Disconnect the starter motor relay trigger terminal connector. 3. Remove the starter motor solenoid relay switch terminal nuts. 4. Remove the engine control sensor wire and the generator wire. 5. Remove the battery cables. 4. Remove the starter motor solenoid relay switch. 1. Remove the bolts. 2. Remove the starter motor solenoid relay switch. INSTALLATION WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM, BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE THE PROTECTIVE CAPS ARE IN PLACE WHEN THE MAINTENANCE IS COMPLETE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications > Page 6494 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications Battery Cable: Specifications Primary Battery Cable Bracket Nut ................................................................................................................................................. 26-34 N.m (19-25 Lb-Ft) Primary Battery Cable Ground Eyelet Nut .......................................................................................................................................... 7-9 N.m (62-80 Lb/In) Auxiliary Battery Ground Cable Bolt to Frame ........................................................................................................................... 12-15 N.m (106-132 Lb/In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 6499 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Primary Battery Cable: Service and Repair Primary REMOVAL 1. Disable the vehicle electrical supply. CAUTION: Failure to accurately follow the battery disconnect procedures will result in vehicle or component damage. 2. Disconnect the primary battery positive cable and remove the hold-down wedge and the primary battery. 3. Remove the four bolts retaining the battery tray and remove the battery tray. 4. Remove the primary battery negative cable ground nut and disengage the eyelet terminal. 5. Remove the starter motor relay B+ terminal rubber cap. 6. Remove the starter motor relay eyelet terminals. 1. Remove the B+ terminal nut and disengage the wire. 2. Remove the enable terminal nut and disengage the wire. 7. Remove the three harness locators in between the primary battery tray mounts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Primary > Page 6502 8. Remove the starter motor/solenoid eyelet terminals. 1. Remove the B+ terminal nut and disengage the wire. 2. Remove the enable nut and disengage the wire. 3. Remove the ground nut and disengage the wire. 9. Disengage the three engine splash shield plastic clips and remove the engine splash shield. 10. Remove the transmission cooler line/primary battery cable bracket nut. 11. Pull the primary battery cable assembly through the engine support crossmember under the vehicle. 12. Disengage the harness locator, located below the battery tray mounts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Primary > Page 6503 13. Pull the primary battery cable assembly out of the vehicle from the engine compartment. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Primary > Page 6504 1. Follow the removal procedure in reverse order. CAUTION: Failure to accurately follow the battery reconnect procedures will result in vehicle or component damage. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Primary > Page 6505 Battery Cable: Service and Repair Auxiliary REMOVAL 1. Disable the vehicle electrical supply. CAUTION: Failure to accurately follow the battery disconnect procedures will result in vehicle or component damage. 2. Disconnect the primary battery positive cable, and remove the hold-down wedge and the primary battery. Remove the auxiliary battery. 3. Remove the four bolts retaining the battery tray and remove the battery tray. 4. Remove three rear harness locators, two to the rear of the vacuum reservoir and one to the front of the vacuum reservoir, along the RH frame rail. 5. Pull the harness through the vacuum reservoir and the frame. 6. Remove three front harness locators, along the RH frame rail, and pull the harness through the front body mounting point. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Primary > Page 6506 7. Remove the engine compartment harness locator. 8. Remove the nut and disengage the harness eyelet. 9. Pull the harness out from the engine compartment. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Primary > Page 6507 1. Follow the removal procedure in reverse order. CAUTION: Failure to accurately follow the battery reconnect procedures will result in vehicle or component damage. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Brush > Component Information > Specifications Alternator Brush: Specifications Generator Regulator and Brushes Mounting Screws .................................................................................................................... 2.3-3.4 N.m (20-30 Lb/In) Brush and Terminal Holder Retaining Screws ............................................................................................................................. 2.8-4.0 N.m (25-35 Lb/In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Brush > Component Information > Specifications > Page 6513 Alternator Brush: Service and Repair GENERATOR BRUSH AND TEMRMINAL HOLDER REMOVAL 1. Remove the Generator (GEN). 2. Remove the generator brush and terminal holder and the Voltage Regulator (VR). 1. Remove the screws. 2. Remove the generator brush and terminal holder and the voltage regulator. 3. Separate the generator brush and terminal holder from the voltage regulator. 1. Remove the screw cap. 2. Remove the screws. 3. Separate the generator brush and terminal holder from the voltage regulator. INSTALLATION 1. Install the brush and terminal holder on the voltage regulator. 1. Position the brush and terminal holder on the voltage regulator. 2. Install the screws. 3. Install the screw cap. CAUTION: Make sure screw cap is installed over test terminal A to prevent accidental shorting of the battery positive (B+) connection. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Brush > Component Information > Specifications > Page 6514 2. Install the generator brush and terminal holder and the voltage regulator. 1. Depress the brushes and insert a wire to hold them. 2. Position the generator brush and terminal holder and the voltage regulator. 3. Install the screws. 4. Remove the wire. 3. Install the generator. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications Voltage Regulator: Specifications Generator Regulator and Brushes Mounting Screws .................................................................................................................... 2.3-3.4 N.m (20-30 Lb/In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 6518 Voltage Regulator: Application and ID Item ...................................................................................................................................................... ............................................................. Specification Voltage Regulator ............................................ ....................................................................................................................................... Internal Rear Mount Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 6519 Voltage Regulator: Service and Repair REMOVAL 1. Remove the Generator (GEN). 2. Remove the generator brush and terminal holder and the Voltage Regulator (VR). 1. Remove the screws. 2. Remove the generator brush and terminal holder and the voltage regulator. 3. Separate the generator brush and terminal holder from the voltage regulator. 1. Remove the screw cap. 2. Remove the screws. 3. Separate the generator brush and terminal holder from the voltage regulator. INSTALLATION 1. Install the brush and terminal holder on the voltage regulator. 1. Position the brush and terminal holder on the voltage regulator. 2. Install the screws. 3. Install the screw cap. CAUTION: Make sure screw cap is installed over Test Terminal A to prevent accidental shorting of the battery positive (B+) connection. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 6520 2. Install the generator brush and terminal holder and the voltage regulator. 1. Depress the brushes and insert a wire to hold them. 2. Position the generator brush and terminal holder and the voltage regulator. 3. Install the screws. 4. Remove the wire. 3. Install the generator. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder Ignition Lock: Customer Interest Ignition Key - Hard To Remove From Ignition Cylinder Article No. 99-16-4 08/09/99 ^ IGNITION KEY - HARD TO REMOVE FROM IGNITION CYLINDER ^ IGNITION KEY - HARD TO TURN FORD: 1992-1999 ECONOLINE 1997-1999 EXPEDITION, F-150, F-25C 1999 SUPER DUTY F SERIES LINCOLN: 1998-1999 NAVIGATOR This TSB article is being republished in its entirety to add vehicles covered by this TSB. ISSUE A hard to turn ignition key, and/or a hard to remove key from ignition cylinder may occur on some vehicles. This may be caused by a misaligned shift column shaft bushing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6530 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6531 ACTION A diagnostic and repair procedure has been developed to correctly repair the concern. Refer to the following Figures 1 through 3 for details. PART NUMBER PART NAME F3TZ-7L278-A Shift Column Shaft Bushing OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-5-9 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991604A Replace Ignition Lock 0.4 Hr. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6532 Cylinder 991604B Replace Bushings 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7335 42 OASIS CODES: 112000, 602300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder Ignition Lock: All Technical Service Bulletins Ignition Key - Hard To Remove From Ignition Cylinder Article No. 99-16-4 08/09/99 ^ IGNITION KEY - HARD TO REMOVE FROM IGNITION CYLINDER ^ IGNITION KEY - HARD TO TURN FORD: 1992-1999 ECONOLINE 1997-1999 EXPEDITION, F-150, F-25C 1999 SUPER DUTY F SERIES LINCOLN: 1998-1999 NAVIGATOR This TSB article is being republished in its entirety to add vehicles covered by this TSB. ISSUE A hard to turn ignition key, and/or a hard to remove key from ignition cylinder may occur on some vehicles. This may be caused by a misaligned shift column shaft bushing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6538 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6539 ACTION A diagnostic and repair procedure has been developed to correctly repair the concern. Refer to the following Figures 1 through 3 for details. PART NUMBER PART NAME F3TZ-7L278-A Shift Column Shaft Bushing OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-5-9 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991604A Replace Ignition Lock 0.4 Hr. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6540 Cylinder 991604B Replace Bushings 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7335 42 OASIS CODES: 112000, 602300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6546 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6547 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6548 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6549 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6550 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 6551 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Replacement, Functional Ignition Switch Lock Cylinder: Service and Repair Replacement, Functional REMOVAL NOTE: The following procedure applies to vehicles that have functional lock cylinders and keys. If key numbers are known, the proper key can be made. 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Position the lock cylinder to RUN. (2) Using a suitable tool, push upward on the cylinder release tab through the hole in the lower shroud while pulling the cylinder outward. INSTALLATION 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Replacement, Functional > Page 6554 Ignition Switch Lock Cylinder: Service and Repair Replacement, Non-Functional REMOVAL NOTE: The following procedure applies to vehicles in which the ignition lock is inoperative and the lock cylinder cannot be rotated due to a lost or broken key, unknown key number, or a cap that has been damaged or broken to the extent that the lock cylinder cannot be rotated. 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 1/8 inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8 inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Replacement, Functional > Page 6555 6. Remove the bearing and the gear. - Thoroughly clean all drill shavings from the steering column and inspect it for damage. INSTALLATION 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. NOTE: Use a new ignition switch lock cylinder. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 6559 Neutral Safety Switch: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 6560 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Cable: Customer Interest Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 6569 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Cable: All Technical Service Bulletins Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 6575 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Description and Operation Starter Drive/Bendix: Description and Operation The starter drive: - is operated by the starter solenoid. - engages the flywheel to turn the engine. - has an internal overrunning clutch to disengage the starter motor when the engine starts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Testing and Inspection > Starter Drive Flywheel Ring Gear Inspection Starter Drive/Bendix: Testing and Inspection Starter Drive Flywheel Ring Gear Inspection 1. Check the wear patterns on the (A) starter drive and the (B) flywheel ring gear. If the wear pattern is normal, install the starter motor. 2. If the (A) starter drive gear and the flywheel ring gear are not fully meshing or the gears are (B) milled or damaged, replace the starter motor and flywheel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Testing and Inspection > Starter Drive Flywheel Ring Gear Inspection > Page 6582 Starter Drive/Bendix: Testing and Inspection Starter Drive Test 1. Remove the starter motor. 2 Secure the starter motor in a vise. 3. Connect the battery ground cable of a fully charged battery to the case of the starter motor. 4. Touch the positive lead from the battery to the S-terminal and verify that the starter drive ejects. CAUTION: Do not leave the positive lead of the battery connected to the starter motor S-terminal for more than 10 seconds. 5. Remove the positive lead from the starter motor. The ejected starter drive should return to its original position. 6. If the starter drive does not eject and return to position, replace the starter motor. 7. Check the starter drive. It should turn freely in one direction, and positively engage to the armature when turned in the opposite direction. If not as specified, replace the starter motor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Specifications Starter Relay: Specifications Starter Motor Solenoid Relay Switch Mounting Bolts ........................................................................................................................ 7-9 N.m (61-79 Lb/In) Starter Motor Relay Mounting Screws ................................................................................................................................................ 7-9 N.m (62-80 Lb/In) Starter Motor Relay B+ and Enable terminal Nuts .............................................................................................................................. 7-9 N.m (62-80 Lb/In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Specifications > Page 6586 Starter Relay: Locations The Starter Motor Relay is located at the RH front corner of the engine compartment, near battery. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Specifications > Page 6587 Starter Relay: Description and Operation The starter motor solenoid relay switch: - controls current to the starter solenoid. - is engaged by the ignition switch. - connects the battery to the starter motor. The Transimission Range (TR) sensor on automatic transmission-equipped vehicles prevents starter motor engagement unless the transmission is in the NEUTRAL or PARK position Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Specifications > Page 6588 Starter Relay: Service and Repair REMOVAL WARNING: WHEN REPAIRING THE STARTER MOTOR OR PERFORMING OTHER UNDERHOOD WORK IN THE VICINITY OF THE STARTER MOTOR, BE AWARE THAT THE HEAVY GAUGE BATTERY INPUT LEAD AT THE STARTER SOLENOID IS ELECTRICALLY HOT AT ALL TIMES. THE PROTECTIVE CAP OR BOOT PROVIDED OVER THIS TERMINAL MUST BE REPLACED AFTER MAINTENANCE IS COMPLETE. MAKE SURE TO DISCONNECT THE BATTERY GROUND CABLE BEFORE WORKING ON THE STARTER MOTOR. 1. Disconnect the battery ground cable. 2. Remove the relay cover. 3. Disconnect the starter motor solenoid relay switch wires and cables. 1. Remove the insulator. 2. Disconnect the starter motor relay trigger terminal connector. 3. Remove the starter motor solenoid relay switch terminal nuts. 4. Remove the engine control sensor wire and the generator wire. 5. Remove the battery cables. 4. Remove the starter motor solenoid relay switch. 1. Remove the bolts. 2. Remove the starter motor solenoid relay switch. INSTALLATION WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM, BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE THE PROTECTIVE CAPS ARE IN PLACE WHEN THE MAINTENANCE IS COMPLETE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Specifications > Page 6589 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Starter Motor Solenoid Relay Switch Mounting Bolts ........................................................................................................................ 7-9 N.m (61-79 Lb/In) Starter Solenoid B-Terminal Nut ....................................................................................................................................................... 10-14 N.m (7-10 Lb/Ft) Starter Solenoid S-Terminal Nut ............................................................................................................................................................. 4-6 N.m (3-4 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 6593 Starter Solenoid: Description and Operation The starter solenoid: - is an electromagnet. - engages the starter drive to the flywheel. - when energized, contacts close, connecting the battery to the starter motor and causing the starter motor to turn the starter drive. - is kept in the energized condition by a hold-in winding until the starter switch is released. When the ignition switch is turned to the START position, the starter motor is energized, connecting the battery to the starter solenoid. The starter solenoid moves the drive lever and drive lever and pin to engage the starter drive with the flywheel ring gear and connects the battery to the starter motor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 6594 Starter Solenoid: Testing and Inspection 1. Check the starter solenoid for continuity between the S- and M-terminals, using the 73 Digital Multimeter. Replace the starter motor if there is no continuity. 2. Check for continuity between the S-terminal and the starter solenoid body, using the digital multimeter. Replace the starter motor if there is no continuity. SOLENOID M-TERMINAL 1. Make sure the starter solenoid is isolated from the starter motor. Using the 73 Digital Multimeter, check for continuity between the S- and M-terminals. Also check for continuity between the S-terminal and starter motor body. If either check shows no continuity, replace the starter motor. 2. Check for continuity between the M-terminal and the B-terminal. If there is continuity, replace the starter motor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6604 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6605 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6606 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6607 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6608 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6609 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6610 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6611 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6617 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6618 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6619 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6620 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6621 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6622 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6623 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6624 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6629 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6630 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6631 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6632 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6633 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6634 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6635 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6636 Fuse: Electrical Diagrams Fuse 4 Fuse 4 - protects the following circuits: - PCM Keep Alive Memory - Instrument Cluster Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6637 Fuse 8 Fuse 8 - protects the following circuits: - Instrument Panel (I/P) Fuse 4 - I/P Fuse 5 - I/P Fuse 10 - I/P Fuse 11 - I/P Fuse 16 - I/P Fuse 22 - I/P Fuse 23 - I/P Fuse 28 - I/P Fuse 38 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6638 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - PCM Power Relay - Engine Compartment Fuse 4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6639 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Auxiliary Battery Relay - Engine Compartment Fuse 14 - Engine Compartment Fuse 22 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6640 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: - Engine Compartment Fuse 26 - Engine Compartment Fuse 27 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6641 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Blower Motor Relay - Blower Motor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6642 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: - Trailer Running Lamps - Trailer Backup Lamps Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6643 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - Main Light Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6644 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6645 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Auxiliary Blower Motor Relay - Remote Keyless Entry Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6646 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Fuel Pump Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6647 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Instrument Panel (I/P) Fuse 40 - I/P Fuse 41 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6648 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - 4 Wheel Anti-Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6649 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: - Electric Brake Controller Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6650 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: - Modified Vehicle Power Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6651 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: - Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6652 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: - Ignition Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6653 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6654 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: - Daytime Running Lamp Module - Horn Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6655 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6656 Power Distribution Fuse 1 Fuse 1 - protects the following circuits: - Rear Anti-Lock Brakes System Module - 4 Wheel Anti-Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6657 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6658 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: - Brake Warning Diode/Resistor - Instrument Cluster - Warning Chime - 4 Wheel Anti-Lock Brakes System Relay - Warning Indicators Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6659 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6660 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: - Main Light Switch - Remote Keyless Entry Module - Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6661 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6662 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6663 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Power Locks (With Remote Keyless Entry) - Illuminated Entry - Warning Chime - Modified Vehicle - Power Mirrors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6664 - Main Light Switch - Courtesy Lamps Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6665 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6666 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6667 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6668 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6669 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6670 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Remote Keyless Entry Module - Power Lock Switches - Memory Lock Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6671 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6672 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Shift Interlock - Speed Control - Daytime Running Lamps Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6673 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6674 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Multi-Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6675 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6676 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Radio Capacitor - Ignition Coil - PCM Diode - PCM Power Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6677 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6679 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6680 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - Wiper Control Module - Windshield Wiper Motor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6681 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6682 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Main Light Switch (External lamps) - Multi-Function Switch (Flash-to-pass) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6683 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6684 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6686 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Brake Pressure Switch - Brake Pedal Position Sensor - Multi-Function Switch (Hazards) - Rear Anti-Lock Brakes System Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6687 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6688 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6689 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: - Transmission Range Sensor - Auxiliary Battery Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6690 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6691 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Blend Door Actuator - Selector Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6692 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6693 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: - Instrument Cluster (Air Bag and Charge Indicator) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6694 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6695 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6696 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6697 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Power Seats Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6698 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - Air Bag Diagnostic Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6699 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6700 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: - Overdrive Cancel Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6701 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6702 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: - Power Windows Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6703 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6704 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: - Memory Power Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6705 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: - Cigar Lighter - Data Link Connector Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6706 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6707 Power Distribution Fuse 24 Fuse 24 - protects the following circuits: - Illuminated Entry Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6708 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6709 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: - Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6710 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 Power Distribution Fuse 28 Fuse 28 - protects the following circuits: - Power Plug Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 Power Distribution Fuse 34 Fuse 34 - protects the following circuits: - Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 Power Distribution Fuse 36 Fuse 36 - protects the following circuits: - Cluster - Radio - Steering Column Assembly Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 Power Distribution Fuse 38 Fuse 38 - protects the following circuits: - Air Bag Diagnostic Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 Power Distribution Fuse 40 Fuse 40 - protects the following circuits: - Modified Vehicle Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 Power Distribution Fuse 41 Fuse 40 - protects the following circuits: - Modified Vehicle Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 Fuse Block: Electrical Diagrams Engine Compartment Fuse Box (Part 1 Of 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 Engine Compartment Fuse Box (Part 2 Of 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 Instrument Panel Fuse Panel (Part 1 Of 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 Instrument Panel Fuse Panel (Part 2 Of 2) Fuse 4 Fuse 4 - protects the following circuits: - PCM Keep Alive Memory - Instrument Cluster Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Instrument Panel (I/P) Fuse 4 - I/P Fuse 5 - I/P Fuse 10 - I/P Fuse 11 - I/P Fuse 16 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 - I/P Fuse 22 - I/P Fuse 23 - I/P Fuse 28 - I/P Fuse 38 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 - PCM Power Relay - Engine Compartment Fuse 4 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Auxiliary Battery Relay - Engine Compartment Fuse 14 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 - Engine Compartment Fuse 22 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: - Engine Compartment Fuse 26 - Engine Compartment Fuse 27 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Blower Motor Relay - Blower Motor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: - Trailer Running Lamps - Trailer Backup Lamps Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - Main Light Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Auxiliary Blower Motor Relay - Remote Keyless Entry Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Fuel Pump Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Instrument Panel (I/P) Fuse 40 - I/P Fuse 41 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - 4 Wheel Anti-Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6748 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: - Electric Brake Controller Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6749 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: - Modified Vehicle Power Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6750 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: - Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6751 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: - Ignition Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: - Daytime Running Lamp Module - Horn Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 Power Distribution Fuse 1 Fuse 1 - protects the following circuits: - Rear Anti-Lock Brakes System Module - 4 Wheel Anti-Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: - Brake Warning Diode/Resistor - Instrument Cluster - Warning Chime - 4 Wheel Anti-Lock Brakes System Relay - Warning Indicators Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: - Main Light Switch - Remote Keyless Entry Module - Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Power Locks (With Remote Keyless Entry) - Illuminated Entry - Warning Chime - Modified Vehicle - Power Mirrors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 - Main Light Switch - Courtesy Lamps Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Remote Keyless Entry Module - Power Lock Switches - Memory Lock Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Shift Interlock - Speed Control - Daytime Running Lamps Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Multi-Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Radio Capacitor - Ignition Coil - PCM Diode - PCM Power Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - Wiper Control Module - Windshield Wiper Motor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6780 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6781 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Main Light Switch (External lamps) - Multi-Function Switch (Flash-to-pass) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6782 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6783 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6784 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6785 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Brake Pressure Switch - Brake Pedal Position Sensor - Multi-Function Switch (Hazards) - Rear Anti-Lock Brakes System Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6786 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: - Transmission Range Sensor - Auxiliary Battery Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Blend Door Actuator - Selector Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6791 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6792 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: - Instrument Cluster (Air Bag and Charge Indicator) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6793 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6794 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6795 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6796 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Power Seats Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6797 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - Air Bag Diagnostic Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6798 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6799 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: - Overdrive Cancel Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: - Power Windows Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: - Memory Power Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: - Cigar Lighter - Data Link Connector Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 Power Distribution Fuse 24 Fuse 24 - protects the following circuits: - Illuminated Entry Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6808 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: - Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6809 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6810 Power Distribution Fuse 28 Fuse 28 - protects the following circuits: - Power Plug Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 Power Distribution Fuse 34 Fuse 34 - protects the following circuits: - Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 Power Distribution Fuse 36 Fuse 36 - protects the following circuits: - Cluster - Radio - Steering Column Assembly Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6814 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6815 Power Distribution Fuse 38 Fuse 38 - protects the following circuits: - Air Bag Diagnostic Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6816 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6817 Power Distribution Fuse 40 Fuse 40 - protects the following circuits: - Modified Vehicle Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6818 Power Distribution Fuse 41 Fuse 40 - protects the following circuits: - Modified Vehicle Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6819 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions Fusible Link: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6824 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6825 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6826 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6827 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6828 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6829 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6830 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6831 Fusible Link: Electrical Diagrams Fuse Link A Fuse Link A - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Power Distribution Fuse Link B Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6832 Fuse Link B - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Power Distribution Fuse Link C Fuse Link C - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6833 Power Distribution Fuse Link D Fuse Link D - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6834 Power Distribution Fuse Link E Fuse Link E - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6835 Power Distribution Fuse Link F Fuse Link F - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6836 Power Distribution Fuse Link G Fuse Link G - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6837 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 Multiple Junction Connector: Diagrams C100 In-Line Connector Faces - C100F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6842 In-Line Connector Faces - C100M Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6843 In-Line Connector Faces - C112 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6844 In-Line Connector Faces - C113 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6845 Multiple Junction Connector: Diagrams C116 In-Line Connector Faces - C116F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6846 In-Line Connector Faces - C116M Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6847 Multiple Junction Connector: Diagrams In-Line Connector Faces - C100F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6848 In-Line Connector Faces - C100M Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6849 In-Line Connector Faces - C112 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6850 In-Line Connector Faces - C113 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6851 In-Line Connector Faces - C116F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6852 In-Line Connector Faces - C116M Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6853 In-Line Connector Faces - C120 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6854 In-Line Connector Faces - C121 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6855 In-Line Connector Faces - C162 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6856 In-Line Connector Faces - C165 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6857 In-Line Connector Faces - C166M Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6858 In-Line Connector Faces - C166F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6859 In-Line Connector Faces - C201 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6860 In-Line Connector Faces - C202 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6861 In-Line Connector Faces - C203 In-Line Connector Faces - C223 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6862 In-Line Connector Faces - C228 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6863 In-Line Connector Faces - C22F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6864 In-Line Connector Faces - C229M Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6865 In-Line Connector Faces - C233 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6866 In-Line Connector Faces - C234M Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6867 In-Line Connector Faces - C234F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6868 In-Line Connector Faces - C300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6869 In-Line Connector Faces - C301 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6870 In-Line Connector Faces - C302 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6871 In-Line Connector Faces - C310 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6872 In-Line Connector Faces - C323 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6873 In-Line Connector Faces - C324 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6874 In-Line Connector Faces - C325 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6875 In-Line Connector Faces - C326 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6876 In-Line Connector Faces - C329 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6877 In-Line Connector Faces - C331 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6878 In-Line Connector Faces - C346 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6879 In-Line Connector Faces - C402 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6880 In-Line Connector Faces - C407 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6881 In-Line Connector Faces - C1158 In-Line Connector Faces - C1159 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay Power Distribution Relay: Locations Auxiliary Battery Relay The Auxiliary Battery Relay is located at the right front of the engine compartment, near battery Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 6886 Power Distribution Relay: Locations Trailer Backup Lamp Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 6887 Engine Compartment Fuse Box (Part 2 Of 2) The Trailer Backup Lamp Relay is located at the LH front of engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 6888 Power Distribution Relay: Locations Trailer Battery Charge Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 6889 Engine Compartment Fuse Box (Part 2 Of 2) The Trailer Battery Charge Relay is located at the LH front of engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 6890 Power Distribution Relay: Locations Trailer Running Lamp Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 6891 Engine Compartment Fuse Box (Part 2 Of 2) The Trailer Running Lamp Relay is located at the LH front of engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Running Lamp Relay Trailer Running Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Running Lamp Relay > Page 6894 Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Running Lamp Relay > Page 6895 Trailer Backup Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay Power Distribution Relay: Locations Auxiliary Battery Relay The Auxiliary Battery Relay is located at the right front of the engine compartment, near battery Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 6901 Power Distribution Relay: Locations Trailer Backup Lamp Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 6902 Engine Compartment Fuse Box (Part 2 Of 2) The Trailer Backup Lamp Relay is located at the LH front of engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 6903 Power Distribution Relay: Locations Trailer Battery Charge Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 6904 Engine Compartment Fuse Box (Part 2 Of 2) The Trailer Battery Charge Relay is located at the LH front of engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 6905 Power Distribution Relay: Locations Trailer Running Lamp Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 6906 Engine Compartment Fuse Box (Part 2 Of 2) The Trailer Running Lamp Relay is located at the LH front of engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Running Lamp Relay Trailer Running Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Running Lamp Relay > Page 6909 Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Running Lamp Relay > Page 6910 Trailer Backup Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness Wiring Harness: Recalls Recall 08V051000: Incorrect Speed Control Jumper Harness MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1994-2003 Ford/E-250 1994-2003 Ford/E-350 1994-2003 Ford/E150 1992-1993 Ford/E250 1992-1993 Ford/E350 1992-1993 Ford/Econoline 1992-2003 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-1997 Ford/Taurus SHO 1993-1995 Lincoln/Town Car 1992-1995 Mercury/Grand Marquis 1992-1998 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: February 01, 2008 NHTSA CAMPAIGN ID NUMBER: 08V051000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control: Cruise Control POTENTIAL NUMBER OF UNITS AFFECTED: 225000 SUMMARY: Ford is recalling 225,000 M?Y 1992-2003 Econoline, M/Y 1993-1995 Taurus SHO, M/Y 1992-1998 Crown Victoria, M/Y 1993 Bronco, F-Series, M/Y 1995-1997 F-Series Super Duty Stripped Chassis, M/Y 1992-1998 Mercury Grand Marquis, and M/Y 1992-1995 Lincoln Town Car vehicles. The affected vehicles were previously repaired using a wiring harness that is not compatible with the vehicle circuit polarity. CONSEQUENCE: As a result, the fuse is located in the output circuit rather than in the intended input power feed circuit, and may not offer the intended protection in the event of an electrical short to ground. REMEDY: Dealers will install a new wiring harness, or replace the mating electrical component. The recall is expected to begin during February 2008. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 08S01. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness > Page 6919 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness Wiring Harness: All Technical Service Bulletins Recall 08V051000: Incorrect Speed Control Jumper Harness MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1994-2003 Ford/E-250 1994-2003 Ford/E-350 1994-2003 Ford/E150 1992-1993 Ford/E250 1992-1993 Ford/E350 1992-1993 Ford/Econoline 1992-2003 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-1997 Ford/Taurus SHO 1993-1995 Lincoln/Town Car 1992-1995 Mercury/Grand Marquis 1992-1998 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: February 01, 2008 NHTSA CAMPAIGN ID NUMBER: 08V051000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control: Cruise Control POTENTIAL NUMBER OF UNITS AFFECTED: 225000 SUMMARY: Ford is recalling 225,000 M?Y 1992-2003 Econoline, M/Y 1993-1995 Taurus SHO, M/Y 1992-1998 Crown Victoria, M/Y 1993 Bronco, F-Series, M/Y 1995-1997 F-Series Super Duty Stripped Chassis, M/Y 1992-1998 Mercury Grand Marquis, and M/Y 1992-1995 Lincoln Town Car vehicles. The affected vehicles were previously repaired using a wiring harness that is not compatible with the vehicle circuit polarity. CONSEQUENCE: As a result, the fuse is located in the output circuit rather than in the intended input power feed circuit, and may not offer the intended protection in the event of an electrical short to ground. REMEDY: Dealers will install a new wiring harness, or replace the mating electrical component. The recall is expected to begin during February 2008. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 08S01. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness > Page 6925 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6935 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6936 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6937 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6938 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6939 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6940 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6941 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6942 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6948 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6949 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6950 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6951 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6952 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6953 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6954 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6955 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6960 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6961 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6962 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6963 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6964 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6965 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6966 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6967 Fuse: Electrical Diagrams Fuse 4 Fuse 4 - protects the following circuits: - PCM Keep Alive Memory - Instrument Cluster Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6968 Fuse 8 Fuse 8 - protects the following circuits: - Instrument Panel (I/P) Fuse 4 - I/P Fuse 5 - I/P Fuse 10 - I/P Fuse 11 - I/P Fuse 16 - I/P Fuse 22 - I/P Fuse 23 - I/P Fuse 28 - I/P Fuse 38 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6969 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - PCM Power Relay - Engine Compartment Fuse 4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6970 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Auxiliary Battery Relay - Engine Compartment Fuse 14 - Engine Compartment Fuse 22 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6971 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: - Engine Compartment Fuse 26 - Engine Compartment Fuse 27 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6972 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Blower Motor Relay - Blower Motor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6973 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: - Trailer Running Lamps - Trailer Backup Lamps Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6974 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - Main Light Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6975 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6976 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Auxiliary Blower Motor Relay - Remote Keyless Entry Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6977 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Fuel Pump Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6978 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Instrument Panel (I/P) Fuse 40 - I/P Fuse 41 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6979 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - 4 Wheel Anti-Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6980 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: - Electric Brake Controller Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6981 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: - Modified Vehicle Power Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6982 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: - Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6983 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: - Ignition Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6984 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6985 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: - Daytime Running Lamp Module - Horn Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6986 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6987 Power Distribution Fuse 1 Fuse 1 - protects the following circuits: - Rear Anti-Lock Brakes System Module - 4 Wheel Anti-Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6988 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6989 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: - Brake Warning Diode/Resistor - Instrument Cluster - Warning Chime - 4 Wheel Anti-Lock Brakes System Relay - Warning Indicators Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6990 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6991 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: - Main Light Switch - Remote Keyless Entry Module - Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6992 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6993 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6994 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Power Locks (With Remote Keyless Entry) - Illuminated Entry - Warning Chime - Modified Vehicle - Power Mirrors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6995 - Main Light Switch - Courtesy Lamps Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6996 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6997 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6998 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6999 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7000 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7001 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Remote Keyless Entry Module - Power Lock Switches - Memory Lock Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7002 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7003 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Shift Interlock - Speed Control - Daytime Running Lamps Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7004 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7005 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Multi-Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7006 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7007 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Radio Capacitor - Ignition Coil - PCM Diode - PCM Power Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7008 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7009 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7011 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - Wiper Control Module - Windshield Wiper Motor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7012 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7013 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Main Light Switch (External lamps) - Multi-Function Switch (Flash-to-pass) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7014 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7015 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7016 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7017 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Brake Pressure Switch - Brake Pedal Position Sensor - Multi-Function Switch (Hazards) - Rear Anti-Lock Brakes System Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7018 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7019 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7020 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: - Transmission Range Sensor - Auxiliary Battery Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7021 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7022 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Blend Door Actuator - Selector Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7023 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7024 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: - Instrument Cluster (Air Bag and Charge Indicator) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7025 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7026 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7027 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7028 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Power Seats Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7029 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - Air Bag Diagnostic Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7030 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7031 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: - Overdrive Cancel Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7032 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7033 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: - Power Windows Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7034 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7035 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: - Memory Power Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: - Cigar Lighter - Data Link Connector Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 Power Distribution Fuse 24 Fuse 24 - protects the following circuits: - Illuminated Entry Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: - Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7041 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7042 Power Distribution Fuse 28 Fuse 28 - protects the following circuits: - Power Plug Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7043 Power Distribution Fuse 34 Fuse 34 - protects the following circuits: - Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7044 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7045 Power Distribution Fuse 36 Fuse 36 - protects the following circuits: - Cluster - Radio - Steering Column Assembly Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7046 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7047 Power Distribution Fuse 38 Fuse 38 - protects the following circuits: - Air Bag Diagnostic Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7048 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7049 Power Distribution Fuse 40 Fuse 40 - protects the following circuits: - Modified Vehicle Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7050 Power Distribution Fuse 41 Fuse 40 - protects the following circuits: - Modified Vehicle Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7051 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7056 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7057 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7058 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7059 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7060 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7061 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7062 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7063 Fuse Block: Electrical Diagrams Engine Compartment Fuse Box (Part 1 Of 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7064 Engine Compartment Fuse Box (Part 2 Of 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7065 Instrument Panel Fuse Panel (Part 1 Of 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7066 Instrument Panel Fuse Panel (Part 2 Of 2) Fuse 4 Fuse 4 - protects the following circuits: - PCM Keep Alive Memory - Instrument Cluster Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7067 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Instrument Panel (I/P) Fuse 4 - I/P Fuse 5 - I/P Fuse 10 - I/P Fuse 11 - I/P Fuse 16 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7068 - I/P Fuse 22 - I/P Fuse 23 - I/P Fuse 28 - I/P Fuse 38 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7069 - PCM Power Relay - Engine Compartment Fuse 4 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Auxiliary Battery Relay - Engine Compartment Fuse 14 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7070 - Engine Compartment Fuse 22 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: - Engine Compartment Fuse 26 - Engine Compartment Fuse 27 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7071 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Blower Motor Relay - Blower Motor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7072 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: - Trailer Running Lamps - Trailer Backup Lamps Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7073 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - Main Light Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7074 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7075 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Auxiliary Blower Motor Relay - Remote Keyless Entry Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7076 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Fuel Pump Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7077 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Instrument Panel (I/P) Fuse 40 - I/P Fuse 41 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7078 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - 4 Wheel Anti-Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7079 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: - Electric Brake Controller Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7080 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: - Modified Vehicle Power Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7081 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: - Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7082 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: - Ignition Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7083 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7084 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: - Daytime Running Lamp Module - Horn Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7085 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7086 Power Distribution Fuse 1 Fuse 1 - protects the following circuits: - Rear Anti-Lock Brakes System Module - 4 Wheel Anti-Lock Brake System Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7087 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7088 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: - Brake Warning Diode/Resistor - Instrument Cluster - Warning Chime - 4 Wheel Anti-Lock Brakes System Relay - Warning Indicators Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7089 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7090 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: - Main Light Switch - Remote Keyless Entry Module - Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7091 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7092 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7093 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Power Locks (With Remote Keyless Entry) - Illuminated Entry - Warning Chime - Modified Vehicle - Power Mirrors Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7094 - Main Light Switch - Courtesy Lamps Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7095 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7096 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7097 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7098 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7099 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7100 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Remote Keyless Entry Module - Power Lock Switches - Memory Lock Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7101 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7102 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Shift Interlock - Speed Control - Daytime Running Lamps Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7103 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7104 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Multi-Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7105 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7106 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Radio Capacitor - Ignition Coil - PCM Diode - PCM Power Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7107 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7108 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7109 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7110 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - Wiper Control Module - Windshield Wiper Motor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7111 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7112 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Main Light Switch (External lamps) - Multi-Function Switch (Flash-to-pass) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7113 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7114 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7115 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7116 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Brake Pressure Switch - Brake Pedal Position Sensor - Multi-Function Switch (Hazards) - Rear Anti-Lock Brakes System Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7117 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7118 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7119 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: - Transmission Range Sensor - Auxiliary Battery Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7120 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7121 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Blend Door Actuator - Selector Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7122 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7123 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: - Instrument Cluster (Air Bag and Charge Indicator) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7124 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7125 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7126 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7127 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Power Seats Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7128 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - Air Bag Diagnostic Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7129 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7130 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: - Overdrive Cancel Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7131 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7132 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: - Power Windows Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7133 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7134 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: - Memory Power Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7135 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: - Cigar Lighter - Data Link Connector Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7136 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7137 Power Distribution Fuse 24 Fuse 24 - protects the following circuits: - Illuminated Entry Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7138 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7139 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: - Radio Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7140 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7141 Power Distribution Fuse 28 Fuse 28 - protects the following circuits: - Power Plug Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7142 Power Distribution Fuse 34 Fuse 34 - protects the following circuits: - Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7143 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7144 Power Distribution Fuse 36 Fuse 36 - protects the following circuits: - Cluster - Radio - Steering Column Assembly Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7145 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7146 Power Distribution Fuse 38 Fuse 38 - protects the following circuits: - Air Bag Diagnostic Monitor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7147 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7148 Power Distribution Fuse 40 Fuse 40 - protects the following circuits: - Modified Vehicle Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7149 Power Distribution Fuse 41 Fuse 40 - protects the following circuits: - Modified Vehicle Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7150 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions Fusible Link: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 7155 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 7156 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 7157 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 7158 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 7159 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 7160 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 7161 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 7162 Fusible Link: Electrical Diagrams Fuse Link A Fuse Link A - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Power Distribution Fuse Link B Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 7163 Fuse Link B - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Power Distribution Fuse Link C Fuse Link C - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 7164 Power Distribution Fuse Link D Fuse Link D - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 7165 Power Distribution Fuse Link E Fuse Link E - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 7166 Power Distribution Fuse Link F Fuse Link F - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 7167 Power Distribution Fuse Link G Fuse Link G - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 7168 Power Distribution Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 Multiple Junction Connector: Diagrams C100 In-Line Connector Faces - C100F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7173 In-Line Connector Faces - C100M Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7174 In-Line Connector Faces - C112 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7175 In-Line Connector Faces - C113 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7176 Multiple Junction Connector: Diagrams C116 In-Line Connector Faces - C116F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7177 In-Line Connector Faces - C116M Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7178 Multiple Junction Connector: Diagrams In-Line Connector Faces - C100F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7179 In-Line Connector Faces - C100M Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7180 In-Line Connector Faces - C112 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7181 In-Line Connector Faces - C113 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7182 In-Line Connector Faces - C116F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7183 In-Line Connector Faces - C116M Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7184 In-Line Connector Faces - C120 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7185 In-Line Connector Faces - C121 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7186 In-Line Connector Faces - C162 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7187 In-Line Connector Faces - C165 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7188 In-Line Connector Faces - C166M Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7189 In-Line Connector Faces - C166F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7190 In-Line Connector Faces - C201 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7191 In-Line Connector Faces - C202 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7192 In-Line Connector Faces - C203 In-Line Connector Faces - C223 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7193 In-Line Connector Faces - C228 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7194 In-Line Connector Faces - C22F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7195 In-Line Connector Faces - C229M Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7196 In-Line Connector Faces - C233 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7197 In-Line Connector Faces - C234M Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7198 In-Line Connector Faces - C234F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7199 In-Line Connector Faces - C300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7200 In-Line Connector Faces - C301 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7201 In-Line Connector Faces - C302 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7202 In-Line Connector Faces - C310 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7203 In-Line Connector Faces - C323 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7204 In-Line Connector Faces - C324 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7205 In-Line Connector Faces - C325 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7206 In-Line Connector Faces - C326 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7207 In-Line Connector Faces - C329 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7208 In-Line Connector Faces - C331 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7209 In-Line Connector Faces - C346 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7210 In-Line Connector Faces - C402 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7211 In-Line Connector Faces - C407 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 7212 In-Line Connector Faces - C1158 In-Line Connector Faces - C1159 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay Power Distribution Relay: Locations Auxiliary Battery Relay The Auxiliary Battery Relay is located at the right front of the engine compartment, near battery Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 7217 Power Distribution Relay: Locations Trailer Backup Lamp Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 7218 Engine Compartment Fuse Box (Part 2 Of 2) The Trailer Backup Lamp Relay is located at the LH front of engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 7219 Power Distribution Relay: Locations Trailer Battery Charge Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 7220 Engine Compartment Fuse Box (Part 2 Of 2) The Trailer Battery Charge Relay is located at the LH front of engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 7221 Power Distribution Relay: Locations Trailer Running Lamp Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 7222 Engine Compartment Fuse Box (Part 2 Of 2) The Trailer Running Lamp Relay is located at the LH front of engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Running Lamp Relay Trailer Running Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Running Lamp Relay > Page 7225 Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Running Lamp Relay > Page 7226 Trailer Backup Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay Power Distribution Relay: Locations Auxiliary Battery Relay The Auxiliary Battery Relay is located at the right front of the engine compartment, near battery Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 7232 Power Distribution Relay: Locations Trailer Backup Lamp Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 7233 Engine Compartment Fuse Box (Part 2 Of 2) The Trailer Backup Lamp Relay is located at the LH front of engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 7234 Power Distribution Relay: Locations Trailer Battery Charge Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 7235 Engine Compartment Fuse Box (Part 2 Of 2) The Trailer Battery Charge Relay is located at the LH front of engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 7236 Power Distribution Relay: Locations Trailer Running Lamp Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Auxiliary Battery Relay > Page 7237 Engine Compartment Fuse Box (Part 2 Of 2) The Trailer Running Lamp Relay is located at the LH front of engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Running Lamp Relay Trailer Running Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Running Lamp Relay > Page 7240 Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Running Lamp Relay > Page 7241 Trailer Backup Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness Wiring Harness: Recalls Recall 08V051000: Incorrect Speed Control Jumper Harness MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1994-2003 Ford/E-250 1994-2003 Ford/E-350 1994-2003 Ford/E150 1992-1993 Ford/E250 1992-1993 Ford/E350 1992-1993 Ford/Econoline 1992-2003 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-1997 Ford/Taurus SHO 1993-1995 Lincoln/Town Car 1992-1995 Mercury/Grand Marquis 1992-1998 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: February 01, 2008 NHTSA CAMPAIGN ID NUMBER: 08V051000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control: Cruise Control POTENTIAL NUMBER OF UNITS AFFECTED: 225000 SUMMARY: Ford is recalling 225,000 M?Y 1992-2003 Econoline, M/Y 1993-1995 Taurus SHO, M/Y 1992-1998 Crown Victoria, M/Y 1993 Bronco, F-Series, M/Y 1995-1997 F-Series Super Duty Stripped Chassis, M/Y 1992-1998 Mercury Grand Marquis, and M/Y 1992-1995 Lincoln Town Car vehicles. The affected vehicles were previously repaired using a wiring harness that is not compatible with the vehicle circuit polarity. CONSEQUENCE: As a result, the fuse is located in the output circuit rather than in the intended input power feed circuit, and may not offer the intended protection in the event of an electrical short to ground. REMEDY: Dealers will install a new wiring harness, or replace the mating electrical component. The recall is expected to begin during February 2008. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 08S01. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness > Page 7250 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness Wiring Harness: All Technical Service Bulletins Recall 08V051000: Incorrect Speed Control Jumper Harness MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1994-2003 Ford/E-250 1994-2003 Ford/E-350 1994-2003 Ford/E150 1992-1993 Ford/E250 1992-1993 Ford/E350 1992-1993 Ford/Econoline 1992-2003 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-1997 Ford/Taurus SHO 1993-1995 Lincoln/Town Car 1992-1995 Mercury/Grand Marquis 1992-1998 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: February 01, 2008 NHTSA CAMPAIGN ID NUMBER: 08V051000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control: Cruise Control POTENTIAL NUMBER OF UNITS AFFECTED: 225000 SUMMARY: Ford is recalling 225,000 M?Y 1992-2003 Econoline, M/Y 1993-1995 Taurus SHO, M/Y 1992-1998 Crown Victoria, M/Y 1993 Bronco, F-Series, M/Y 1995-1997 F-Series Super Duty Stripped Chassis, M/Y 1992-1998 Mercury Grand Marquis, and M/Y 1992-1995 Lincoln Town Car vehicles. The affected vehicles were previously repaired using a wiring harness that is not compatible with the vehicle circuit polarity. CONSEQUENCE: As a result, the fuse is located in the output circuit rather than in the intended input power feed circuit, and may not offer the intended protection in the event of an electrical short to ground. REMEDY: Dealers will install a new wiring harness, or replace the mating electrical component. The recall is expected to begin during February 2008. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 08S01. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness > Page 7256 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' Alignment: Customer Interest Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 7266 Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 7267 (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 7268 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 7269 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' Alignment: All Technical Service Bulletins Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 7275 Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 7276 (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 7277 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 7278 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7283 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7284 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7285 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7286 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7287 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7288 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7289 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7290 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7291 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7292 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7293 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7294 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7295 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7296 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7297 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7298 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7299 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7300 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7301 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7302 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7303 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7304 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7305 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7306 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7307 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7308 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7309 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7310 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7311 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7312 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7313 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7314 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7315 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7316 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7317 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7318 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7319 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7320 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7321 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7322 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7323 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7324 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7325 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7326 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7327 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7328 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7329 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7330 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7331 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7332 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7333 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7334 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7335 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7336 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7337 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7338 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7339 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7340 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7341 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7342 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7343 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7344 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7345 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7346 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7347 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7348 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7349 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7351 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7352 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7353 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7354 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7355 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7356 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7357 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7358 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7359 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7360 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7361 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7362 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7363 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7364 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7365 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7366 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7367 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7368 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7369 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7370 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7371 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7372 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7373 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7374 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7375 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7376 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7377 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-17-12 > Sep > 98 > Wheel Alignment - Procedures For Incomplete Vehicles Alignment: All Technical Service Bulletins Wheel Alignment - Procedures For Incomplete Vehicles Article No. 98-17-12 09/01/98 ALIGNMENT - ALIGNMENT PROCEDURES FOR INCOMPLETE VEHICLES - SERVICE TIP LIGHT TRUCK: 1998 ECONOLINE ISSUE Wheel alignment on incomplete vehicles is not reimbursable. ACTION After build-up of incomplete vehicles, realign vehicles to factory specification. Setting vehicles to factory specification should resolve all alignment issues. Refer to the following text for details. INCOMPLETE VEHICLES (Cut-Away, Strip Chassis) Wheel alignment on incomplete vehicles (cut-away, strip chassis) is not reimbursable due to installation of special bodies or equipment after the vehicles leave the assembly plant. If readjustment is necessary, follow the instructions in the 1998 Econoline Workshop Manual to reset the alignment back to OEM specification. The cost for such realignment is the responsibility of the final stage manufacturer or modifier. INCOMPLETE VEHICLES (Conversion Vans) On incomplete vehicles (conversion vans), toe must be checked by the final stage manufacturer and is not reimbursable. Should toe readjustment be necessary, follow the instructions in the 1998 Econoline Workshop Manual to reset the alignment to OEM specification. The cost for such realignment is the responsibility of the final stage manufacturer or modifier. Note that occasionally van conversions will require additional adjustments (i.e., caster and camber). If such adjustments are required, they are reimbursable per the Warranty and Policy Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7387 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7388 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7389 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7390 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7391 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7392 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7393 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7394 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7395 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7396 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7397 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7398 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7399 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7400 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7401 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7402 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7403 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7404 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7405 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7406 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7407 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7408 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7409 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7410 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7411 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7412 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7413 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7414 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7415 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7416 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7417 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7418 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7419 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7420 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7421 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7422 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7423 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7424 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7425 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7426 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7427 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7428 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7429 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7430 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7431 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7432 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7433 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7434 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7435 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7436 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7437 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7438 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7439 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7440 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7441 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7442 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7443 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7444 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7445 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7446 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7447 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7448 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7449 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7450 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7451 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7452 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7453 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7454 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7455 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7456 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7457 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7458 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7459 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7460 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7461 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7462 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7463 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7464 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7465 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7466 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7467 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7468 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7469 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7470 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7471 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7472 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7473 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7474 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7475 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7476 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7477 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7478 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7479 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7480 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 7481 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 98-17-12 > Sep > 98 > Wheel Alignment - Procedures For Incomplete Vehicles Alignment: All Technical Service Bulletins Wheel Alignment - Procedures For Incomplete Vehicles Article No. 98-17-12 09/01/98 ALIGNMENT - ALIGNMENT PROCEDURES FOR INCOMPLETE VEHICLES - SERVICE TIP LIGHT TRUCK: 1998 ECONOLINE ISSUE Wheel alignment on incomplete vehicles is not reimbursable. ACTION After build-up of incomplete vehicles, realign vehicles to factory specification. Setting vehicles to factory specification should resolve all alignment issues. Refer to the following text for details. INCOMPLETE VEHICLES (Cut-Away, Strip Chassis) Wheel alignment on incomplete vehicles (cut-away, strip chassis) is not reimbursable due to installation of special bodies or equipment after the vehicles leave the assembly plant. If readjustment is necessary, follow the instructions in the 1998 Econoline Workshop Manual to reset the alignment back to OEM specification. The cost for such realignment is the responsibility of the final stage manufacturer or modifier. INCOMPLETE VEHICLES (Conversion Vans) On incomplete vehicles (conversion vans), toe must be checked by the final stage manufacturer and is not reimbursable. Should toe readjustment be necessary, follow the instructions in the 1998 Econoline Workshop Manual to reset the alignment to OEM specification. The cost for such realignment is the responsibility of the final stage manufacturer or modifier. Note that occasionally van conversions will require additional adjustments (i.e., caster and camber). If such adjustments are required, they are reimbursable per the Warranty and Policy Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7486 Alignment: By Symptom Technical Service Bulletin # 02-16-8 Date: 020819 Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7487 front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7488 (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7489 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7490 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Technical Service Bulletin # 02-16-8 Date: 020819 Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7491 First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7492 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7493 (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7494 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 7495 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Technical Service Bulletin # 98-17-12 Date: 980901 Wheel Alignment - Procedures For Incomplete Vehicles Article No. 98-17-12 09/01/98 ALIGNMENT - ALIGNMENT PROCEDURES FOR INCOMPLETE VEHICLES - SERVICE TIP LIGHT TRUCK: 1998 ECONOLINE ISSUE Wheel alignment on incomplete vehicles is not reimbursable. ACTION After build-up of incomplete vehicles, realign vehicles to factory specification. Setting vehicles to factory specification should resolve all alignment issues. Refer to the following text for details. INCOMPLETE VEHICLES (Cut-Away, Strip Chassis) Wheel alignment on incomplete vehicles (cut-away, strip chassis) is not reimbursable due to installation of special bodies or equipment after the vehicles leave the assembly plant. If readjustment is necessary, follow the instructions in the 1998 Econoline Workshop Manual to reset the alignment back to OEM specification. The cost for such realignment is the responsibility of the final stage manufacturer or modifier. INCOMPLETE VEHICLES (Conversion Vans) On incomplete vehicles (conversion vans), toe must be checked by the final stage manufacturer and is not reimbursable. Should toe readjustment be necessary, follow the instructions in the 1998 Econoline Workshop Manual to reset the alignment to OEM specification. The cost for such realignment is the responsibility of the final stage manufacturer or modifier. Note that occasionally van conversions will require additional adjustments (i.e., caster and camber). If such adjustments are required, they are reimbursable per the Warranty and Policy Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Alignment: Specifications Alignment Camber/Caster Service Adjuster Caster LH ........................................................................................................................................................ ................................................... 4.75° ± 2.75° RH ............................................................................. .............................................................................................................................. 4.75° ± 2.75° Total/Split ............................................................................................................................................. ..................................................... -1.0° ± 0.5° Camber LH ........................................................................................................................................................ ....................................................... 0.5° ± 0.5° RH ............................................................................. .................................................................................................................................. 0.5° ± 0.5° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.5° Toe (Positive Value Is Toe-in, Negative Value Is Toe-out) Total/Split ............................................................................................................................................. .................................................. 0.06° ± 0.25° Dogtracking - Maximum (Centerline of front tires compared to centerline of rear tires) ............................................................................................................................................... 30 mm (1.25 inch) Clear Vision (Negative value is counterclockwise) ............................................................................................................................ .............................................................. 0° ± 3° Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 7498 Alignment: Description and Operation WHEEL ALIGNMENT ANGLES Caster and camber correction requirements are factory-determined. Adjusters are available to correct a caster/camber measurement that does not meet specification. Before changing the production caster/camber adjuster, thoroughly inspect the suspension system to locate worn or damaged components that may have caused the setting to change. Negative and Positive Camber 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 and Frame Angle (Positive Caster Shown) CASTER Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Positive Toe (Toe In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 7499 Negative Toe TOE The vehicle toe setting: affects tire wear and directional stability. - must be checked after adding aftermarket equipment, such as a snowplow or body. Wheel Track WHEEL TRACK Dogtracking DOGTRACKING 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 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 7500 road. SHIMMY 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. 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 (i.e., wind, road camber). 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 readability problem, it is important to understand the difference between wander and poor groove feel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber/Caster Service Adjuster Chart Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber/Caster Service Adjuster Chart > Page 7503 Alignment: Service and Repair Caster and Camber 1. Using an alignment rack and manufacturer's instructions, measure the caster and camber. - Note any difference between the actual measurements and the specification. This information will be used to select the correct service adjuster. CAUTION: Do not bend axles or radius arms to change alignment. 2. Raise and support the front end. 3. Remove the front wheel(s). 4. Check the type and orientation of the installed adjuster. a. Production adjusters have a round flange, a side tab and the amounts of caster and camber stamped in the top of the adjuster. - The first number is the amount of caster; the second number is the amount of camber in degrees if the adjuster is installed in the right-hand axle position. - If the adjuster is in the left-hand axle, the caster number is the opposite sign of the number shown. For example, a positive amount in the right-hand axle is a negative amount in the left axle, and a negative amount in the right-hand is a positive in the left-hand position. b. Service adjusters have a hex flange, no side tab and the adjustment amount of the caster and camber stamped into the top. 5. Select a new service adjuster and its orientation in the axle to obtain the optimum caster/camber. - Note that the caster change or camber change required to obtain the optimum settings must be added to amounts of caster/camber in the old or production adjuster. - Use this example as a guide. If caster must be reduced 1 degree and camber increased +0.75 degree at the LH wheel, and the existing adjuster has +0.25-degree caster as installed, select the 1-degree service adjuster and orient the slot 225 degrees from the straight-ahead position. In all cases, select the adjuster and orientation that will bring the alignment closest to the optimal settings. NOTE: The assembly plant sometimes builds vehicles with adjusters that are not 0-degree type to control alignment. The following chart shows the alignment changes that will occur if the vehicle was originally built with 0-degree adjusters. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber/Caster Service Adjuster Chart > Page 7504 6. Loosen the pinch bolt. Remove the adjuster out of the axle. 7. Install the new service adjuster. Orient the slot as noted in Step 5. (1) Position the new adjuster as specified in the chart. (2) Tighten the pinch bolt. 8. Install the front wheel. 9. Lower the front end. 10. Check the alignment. If not at optimal caster/camber specification, additional adjustment of the rotational orientation of the adjuster is required. 11. Once optimal caster/camber has been achieved, reset the toe and clear vision to optimal settings. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber/Caster Service Adjuster Chart > Page 7505 Alignment: Service and Repair Toe 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings. 4. Loosen the nuts. - Clean and lubricate the steering linkage and tie rod end threads. 5. Rotate the adjusting sleeves to obtain the correct toe setting. 6. Tighten the nuts. Position the RH adjusting sleeve clamp opening downward within 45 degrees of vertical. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber/Caster Service Adjuster Chart > Page 7506 7. Tighten the nuts. Position the LH adjusting sleeve clamp opening upward within 45 degrees of vertical. 8. Recheck the toe settings. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair REMOVAL CAUTION: The steering column must be in the locked position, or the lower end of the column wired in such a way that the steering column does not rotate, resulting in damage to the air bag sliding contact. NOTE: Discard the upper intermediate shaft to steering column shaft bolt upon removal. Do not reuse; replace with new bolts. 1. Remove the bolt retaining the upper shaft assembly U-joint to the steering column center shaft. 2. Remove the shock absorber electronic steering sensor. (1) Disconnect the electrical connector. (2) Remove the screws. (3) Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. (1) Remove the steering column lower bearing spring. (2) Remove the sensor ring. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 7512 2. Install the shock absorber electronic steering sensor. (1) Position the shock absorber electronic steering sensor. (2) Install the screws. (3) Connect the electrical connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair REMOVAL CAUTION: The steering column must be in the locked position, or the lower end of the column wired in such a way that the steering column does not rotate, resulting in damage to the air bag sliding contact. NOTE: Discard the upper intermediate shaft to steering column shaft bolt upon removal. Do not reuse; replace with new bolts. 1. Remove the bolt retaining the upper shaft assembly U-joint to the steering column center shaft. 2. Remove the shock absorber electronic steering sensor. (1) Disconnect the electrical connector. (2) Remove the screws. (3) Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. (1) Remove the steering column lower bearing spring. (2) Remove the sensor ring. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Page 7517 2. Install the shock absorber electronic steering sensor. (1) Position the shock absorber electronic steering sensor. (2) Install the screws. (3) Connect the electrical connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair Center Link: Service and Repair REMOVAL NOTE: Replace the steering sector shaft arm drag link or tie rod end if the following conditions are present: Ball stud is excessively loose in the socket of the tie rod end. - Steering sector shaft arm drag link is bent. - Taper for the tie rod end is loose. Replace the front suspension steering ball stud dust seal if any nicks, cuts or tears are present. Do not attempt to straighten a steering sector shaft arm drag link or tie rod end. 1. Remove the steering drag link castellated nuts. (1) Remove the cotter pins and discard. (2) Remove the castellated nuts. 2. Remove the outer tie rod end from the RH steering knuckle. 3. Remove the LH inner tie rod end from the steering sector shaft arm drag link. 4. Remove the steering sector shaft arm drag lint castellated nut. (1) Remove and discard the cotter pin. (2) Remove the nut. 5. Using the Pitman Arm Puller, separate the steering sector shaft arm drag link. 6. Remove the tie rod adjusting sleeve from the drag link. Count the number of turns required to remove the tie rod adjusting sleeve. INSTALLATION 1. Follow the removal procedure in reverse order. Install new cotter pins. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Page 7522 2. Tighten the castellated nuts and the tie rod adjusting sleeve bolts. NOTE: The two bolts and nuts on the tie rod adjusting sleeve clamp for the tie rod end must be positioned within a limit of 45 degrees (±). The threaded ends of the bolts on the left tie rod end point toward the front of the vehicle. The threaded ends on the right tie rod end face rearward. 3. Check toe-in. 4. Check clear vision. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair Pitman Arm: Service and Repair REMOVAL NOTE: Replace the steering gear sector shaft arm if it is bent. If the steering gear sector shaft arm is bent, also check the drag link, steering tie rod, tie rod adjustment sleeves and tie rod ball studs for signs of damage. Replace damaged steering linkage as required. Do not attempt to straighten the steering gear sector shaft arm or any other steering linkage components. 1. Raise and support vehicle. 2. Remove steering sector shaft arm drag link castellated nut. (1) Remove and discard cotter pin. (2) Remove castellated nut. 3. Use Pitman Arm Puller to separate the steering sector shaft arm drag link. 4. Scribe alignment marks on the steering gear sector shaft and steering gear sector shaft arm. 5. Remove the sector shaft arm nut and washer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair > Page 7526 6. Using Pitman Arm Puller, remove the steering gear sector shaft arm. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair > Page 7527 Special Tool(s) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair CAUTION: If the air is not purged from the power steering system correctly, premature power steering pump failure could result. This condition can occur on pre-delivery vehicles with evidence of aerated fluid on vehicles that have had steering component repairs. 1. Remove the reservoir cap. Check the fluid. - Use Motorcraft MERCON Multi-Purpose ATF XT-2-QDX or MERCON equivalent. NOTE: A whine heard from the power steering pump may be caused by air in the system. The power steering purge procedure must be performed prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid. 2. Tightly insert the stopper of the vacuum pump into the reservoir. 3. Start the vehicle. 4. Apply maximum vacuum and maintain it for a minimum of three minutes with the engine speed set at idle. 5. Release the vacuum and remove the vacuum pump. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 7532 6. Fill the reservoir. - Use Motorcraft MERCON Multi-Purpose ATF XT-2-QDX or MERCON equivalent. CAUTION: Do not overfill the reservoir. 7. Reinstall the vacuum pump. Apply and maintain maximum vacuum. 8. Cycle the steering wheel fully to the left and right every 30 seconds for approximately five minutes. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump could occur. 9. Stop the engine, release the vacuum, and remove the vacuum pump. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 7533 10. Install the reservoir cap. 11. Check for fluid leaks at all of the connections. If the power steering fluid shows signs of air, repeat this procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing Power Steering Fluid: Customer Interest Steering/Brakes - Brake Pedal Kick-Back/Grabbing TSB 07-11-10 06/11/07 BRAKE PEDAL KICKBACK OR GRABBING FORD: 1997-2007 E-Series 1999-2008 F-Super Duty 2000-2005 Excursion This article supersedes TSB 99-25-8 to update the vehicle model years. ISSUE Some 1999-2008 F-Super Duty, 2000-2005 Excursion, and 1997-2007 E-Series vehicles equipped with Hyrdo-Boost(R) brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes. This may be caused by contamination within the power steering system. ACTION Filter the power steering fluid by installing a temporary filter in the power steering system. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Verify that the line from the pump and the line to the gear at the Hydro-Boost(R) are in their correct orientation (and not crossed). The passenger side goes to the pump, the driver side goes to the gear. 2. Attach a pinch-off clamp to the lower power steering hose approximately 6" (15 cm) from the lower port of the power steering cooler to keep fluid from emptying out of the system when the hose is disconnected. 3. Disconnect the power steering hose from the lower port on the cooler. Cap the cooler port to minimize fluid leakage and immediately install the temporary filter in line with the power steering hose using hose clamps to retain the filter (the filter needs to go in the low pressure line that goes from gear to cooler to reservoir, where it would be most accessible). 4. Attach the other end of the filter to the cooler using the clamps provided. 5. Remove the pinch-off clamp from the power steering hose. FILTERING PROCEDURE CAUTION BE SURE THAT THE PARKING BRAKE IS APPLIED DURING THE FOLLOWING STEPS 1-7. 1. Check power steering fluid level before starting the vehicle. 2. Start the vehicle and allow it to idle for approximately 15 seconds. NOTE DO NOT HOLD THE STEERING AT LOCK FOR MORE THAN 5 SECONDS. 3. Turn steering wheel lock-to-lock 10 times. 4. Pump service brake pedal hard to floor 25 times. 5. Turn steering wheel lock-to-lock 5 times. 6. Remove the filter and reconnect the power steering line to the cooler. Discard the filter. Fill the power steering system. Refer to Workshop Manual (WSM), Section 211-00 Power Steering System Filling. 7. With the engine at idle, gradually apply the brake pedal until fully applied. If the brake pedal kickback persists, replace the Hydro-Boost(R) brake booster. Refer to WSM, Section 206-07. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing > Page 7542 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 MTO71110 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 2005 07 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing Power Steering Fluid: All Technical Service Bulletins Steering/Brakes - Brake Pedal Kick-Back/Grabbing TSB 07-11-10 06/11/07 BRAKE PEDAL KICKBACK OR GRABBING FORD: 1997-2007 E-Series 1999-2008 F-Super Duty 2000-2005 Excursion This article supersedes TSB 99-25-8 to update the vehicle model years. ISSUE Some 1999-2008 F-Super Duty, 2000-2005 Excursion, and 1997-2007 E-Series vehicles equipped with Hyrdo-Boost(R) brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes. This may be caused by contamination within the power steering system. ACTION Filter the power steering fluid by installing a temporary filter in the power steering system. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Verify that the line from the pump and the line to the gear at the Hydro-Boost(R) are in their correct orientation (and not crossed). The passenger side goes to the pump, the driver side goes to the gear. 2. Attach a pinch-off clamp to the lower power steering hose approximately 6" (15 cm) from the lower port of the power steering cooler to keep fluid from emptying out of the system when the hose is disconnected. 3. Disconnect the power steering hose from the lower port on the cooler. Cap the cooler port to minimize fluid leakage and immediately install the temporary filter in line with the power steering hose using hose clamps to retain the filter (the filter needs to go in the low pressure line that goes from gear to cooler to reservoir, where it would be most accessible). 4. Attach the other end of the filter to the cooler using the clamps provided. 5. Remove the pinch-off clamp from the power steering hose. FILTERING PROCEDURE CAUTION BE SURE THAT THE PARKING BRAKE IS APPLIED DURING THE FOLLOWING STEPS 1-7. 1. Check power steering fluid level before starting the vehicle. 2. Start the vehicle and allow it to idle for approximately 15 seconds. NOTE DO NOT HOLD THE STEERING AT LOCK FOR MORE THAN 5 SECONDS. 3. Turn steering wheel lock-to-lock 10 times. 4. Pump service brake pedal hard to floor 25 times. 5. Turn steering wheel lock-to-lock 5 times. 6. Remove the filter and reconnect the power steering line to the cooler. Discard the filter. Fill the power steering system. Refer to Workshop Manual (WSM), Section 211-00 Power Steering System Filling. 7. With the engine at idle, gradually apply the brake pedal until fully applied. If the brake pedal kickback persists, replace the Hydro-Boost(R) brake booster. Refer to WSM, Section 206-07. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 07-11-10 > Jun > 07 > Steering/Brakes - Brake Pedal Kick-Back/Grabbing > Page 7548 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 MTO71110 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 2005 07 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 07-1-7 > Jan > 07 > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 07-1-7 > Jan > 07 > Steering - Mercon V(R) Fluid Usage > Page 7553 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 07-1-7 > Jan > 07 > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 07-1-7 > Jan > 07 > Steering - Mercon V(R) Fluid Usage > Page 7559 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Fill to line in power steering fluid reservoir. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 7562 Power Steering Fluid: Fluid Type Specifications FLUID TYPE ........................................................................................................................................................... Ford E6AZ-19582-AA or equivalent Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications Power Steering Fluid Cooler: Specifications TORQUE SPECIFICATIONS Power Steering Cooler Bolts .................................................................................................................................................. 9-12 Nm (80-106 inch lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 7566 Power Steering Fluid Cooler: Service and Repair REMOVAL 1. Remove the transmission fluid cooler. 2. Disconnect the hoses at the fluid cooler 3. Remove the two power steering cooler bolts and remove the power steering cooler. INSTALLATION 1. Follow the removal procedure in reverse order. - Install the transmission cooler. - Fill, purge and leak check the system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 REMOVAL 1. Raise and support vehicle. 2. Remove the return hose from the power steering pump and drain the power steering oil reservoir. 3. Lower the vehicle. 4. Lift the reservoir out of the reservoir bracket. 5. Compress clamps and disconnect the power steering return hose and the power steering reservoir pump hose. 6. Remove the power steering oil reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. 2. Fill, purge and leak check the system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications TORQUE SPECIFICATIONS Pressure Hose Fitting .......................................................................................................................... ....................................... 17-23 Nm (13-17 ft. lbs.) Pressure Hose At Steering Gear ................................................................................................................................................. 17-23 Nm (13-17 ft. lbs.) Return Hose Fitting At Steering Gear ........................................................................................................................................ 17-23 Nm (13-17 ft. lbs.) Power Steering Metal Line Retainer Nuts .................................................................................................................................. 15-17 Nm (11-13 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 7573 Power Steering Line/Hose: Service and Repair 1. When connecting a fitting with a seal ring, the ring must be replaced. - The Seal Replacer is used to install the return line connector seal and the pressure line connector seal. 2. Fill and leak check the system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 7574 Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications TORQUE SPECIFICATIONS Power Steering Pump Upper Bolts ............................................................................................................................................. 20-30 Nm (15-22 ft. lbs.) Power Steering Pump Lower Bolt .............................................................................................................................................. 20-30 Nm (15-22 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 7579 Power Steering Pump: Pressure, Vacuum and Temperature Specifications OPERATIONAL SPECIFICATIONS Type ..................................................................................................................................................... ........................................................................ CIII Max. Pressure @ 74-80° C (165-175° F) And Engine Speed Set At 1500 RPM ..................................................................................................................... ........................................... 1034 kPa (150 psi) Relief Pressure ............................................................................................................................................................. 9,000-9,900 kPa (1,300-1,430 psi) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 7580 Power Steering Pump: Capacity Specifications OPERATIONAL SPECIFICATIONS Type ..................................................................................................................................................... ........................................................................ CIII Flow Rate @ 74-80° C (165-175° F) And Engine Speed Set At 1500 RPM ................................................................................................................................. 10.6-12.0 Liters/Minute (2.8-3.2 gpm) Min. Flow Rate @ 74-80° C (165-175° F), Power Steering Analyzer Set At 5102 KPa (750 Psi) And Engine Speed Set At Idle ......................................................................................................................................... 5.3 Liters/Minute (1.4 gpm) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 7581 Power Steering Pump: Application and ID The pump identification code is located on a tag attached to the power steering pump. CAUTION: Always use the ID code when ordering service parts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 7582 Power Steering Pump: Description and Operation Power Steering Pump The CIII power steering pump has the following features: - It is a belt-driven, vane-type, power steering pump. - It is mounted directly to the engine block by three bolts. - The power steering pump is replaced as an assembly. - An identification tag attached to the power steering pump indicates the model number and bar code. Refer to these when pump replacement is required. - The power steering pump uses a quick connect fitting for the power steering pressure hose. - The power steering oil reservoir is mounted on the LH side of the upper radiator support crossmember. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 REMOVAL 1. Remove the drive belt. 2. Raise and support the vehicle. 3. Disconnect the power steering reservoir pump hose from the power steering pump. - Drain the power steering oil reservoir. 4. Disconnect the high-pressure fitting from the power steering pump. 5. Remove the two top power steering pump bolts. 6. Remove the lower pump bolt and remove the power steering pump. INSTALLATION 1. Position the power steering pump and loosely install the three bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7585 2. Tighten the two upper power steering pump bolts. 3. Tighten the lower power steering pump bolt. 4. Install a new power steering seal on the power steering pressure fitting by stretching the seal over the seal replacer until it is large enough to slip over the threads of the fitting. 5. Install the power steering pressure fitting to the power steering pump. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7586 6. Install the power steering return hose to the power steering pump. 7. Lower the vehicle and install the drive belt. 8. Install the drive belt. 9. Fill, purge and leak check the system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7587 Power Steering Pump: Service and Repair Power Steering Pump Pulley REMOVAL 1. Remove the power steering pump. 2. Hold the Steering Pump Pulley Remover and rotate the forcing bolt to remove the power steering pump pulley. INSTALLATION 1. Thread the forcing bolt into the power steering pump and turn Steering Pump Pulley Replacer to install the pump pulley. 2. Install the power steering pump. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering Pump Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering Pump > Page 7590 Special Tool(s) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair REMOVAL CAUTION: The steering column must be in the locked position, or the lower end of the column wired in such a way that the steering column does not rotate, resulting in damage to the air bag sliding contact. NOTE: Discard the upper intermediate shaft to steering column shaft bolt upon removal. Do not reuse; replace with new bolts. 1. Remove the bolt retaining the upper shaft assembly U-joint to the steering column center shaft. 2. Remove the shock absorber electronic steering sensor. (1) Disconnect the electrical connector. (2) Remove the screws. (3) Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. (1) Remove the steering column lower bearing spring. (2) Remove the sensor ring. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 7595 2. Install the shock absorber electronic steering sensor. (1) Position the shock absorber electronic steering sensor. (2) Install the screws. (3) Connect the electrical connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair REMOVAL CAUTION: The steering column must be in the locked position, or the lower end of the column wired in such a way that the steering column does not rotate, resulting in damage to the air bag sliding contact. NOTE: Discard the upper intermediate shaft to steering column shaft bolt upon removal. Do not reuse; replace with new bolts. 1. Remove the bolt retaining the upper shaft assembly U-joint to the steering column center shaft. 2. Remove the shock absorber electronic steering sensor. (1) Disconnect the electrical connector. (2) Remove the screws. (3) Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. (1) Remove the steering column lower bearing spring. (2) Remove the sensor ring. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 7599 2. Install the shock absorber electronic steering sensor. (1) Position the shock absorber electronic steering sensor. (2) Install the screws. (3) Connect the electrical connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect the battery ground cable(s). WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable(s). REACTIVATION PROCEDURE 1. Disconnect the battery ground cables. WARNING: THE AIR BAG SIMULATORS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Reconnect the passenger air bag module. 7. Reconnect the battery ground cable(s). 8. Prove out the system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 7605 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the primary crash sensor connected and mounted to the vehicle? [ ] 2. Is the three-way connector at the base of the steering column connected? [ ] 3. Are the air bag modules and belt and buckle assembly pretensioners or air bag simulators connected? [ ] 4. Is the air bag Electronic Crash Sensor (ECS) module connected? [ ] 5. Is the vehicle battery connected? [ ] Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation The key-in-ignition warning chime/buzzer will sound continuously when the ignition key is in the ignition switch lock cylinder with the key OFF and the driver door open. The chime/buzzer will continue to sound until the key is removed from the ignition switch lock cylinder or the driver door is closed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Specifications Steering Damper: Specifications TORQUE SPECIFICATIONS Nut, Steering Damper RH Bracket ............................................................................................................................................. 68-92 Nm (50-68 ft. lbs.) Nut, Steering Damper LH Bracket ............................................................................................................................................. 68-92 Nm (50-68 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Specifications > Page 7612 Steering Damper: Service and Repair REMOVAL 1. Remove the nut retaining the damper to the bracket on the steering linkage. 2. Remove the nut and bolt retaining the damper to the RH damper bracket. NOTE: The RH damper bracket and the steering linkage bracket can be removed from the vehicle, if necessary, by removing the retaining bolts and nuts. 3. Remove the damper from the mounting brackets. INSTALLATION 1. Install the damper into the mounting brackets. NOTE: When installing a new steering linkage bracket, make sure the bracket is properly positioned on the steering sector shaft arm drag link before tightening the U-bolt retaining nuts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Specifications > Page 7613 2. Install the bolt and nut retaining the damper to the RH bracket. 3. Install the nut retaining the damper to the steering linkage LH bracket. 4. Rotate the steering wheel from stop to stop. Verify that the steering linkage damper is not bottoming out and that the steering linkage reaches its full travel when the steering wheel is turned from stop to stop. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Specifications > Page 7614 Special Tool(s) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Sector Shaft > Component Information > Specifications Sector Shaft: Specifications OPERATIONAL SPECIFICATIONS Sector Shaft Rotating Torque ........................................................................................................................................................... 2.0 Nm (18 inch lbs.) TORQUE SPECIFICATIONS Nut, Steering Sector Shaft Arm ....................................................................................................................................... 230-310 Nm (170-228 ft. lbs.) Steering Sector Shaft Arm Drag Link Castellated Nut .................................................................................................................................... ............................... 77-104 Nm (57-76 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications Steering Shaft: Specifications TORQUE SPECIFICATIONS Intermediate Shaft Pinch Bolt .................................................................................................................................................... 22-28 Nm (16-21 ft. lbs.) Intermediate Shaft To Steering Gear Bolt ................................................................................................................................... 41-57 Nm (30-42 ft. lbs.) Intermediate Shaft To Steering Column Bolt ............................................................................................................................. 41-57 Nm (30-42 ft. lbs.) Steering Boot Nut ........................................................................................................................ ............................................... 5-7 Nm (44-62 inch lbs.) Upper Shaft Steering Column Center Shaft Bolt ................................................................................................................................. ................................. 21-29 Nm (15-21 ft. lbs.) Lower Shaft To Upper Shaft Bolt .............................................................................................................................................. 41-57 Nm (30-42 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 7622 Steering Shaft: Service and Repair REMOVAL CAUTION: Make sure the steering column is in the locked position, or pin the lower end of the steering column center shaft to prevent the steering wheel from being turned. Turning the steering wheel with the intermediate shaft removed can cause damage to the clockspring. 1. Center the front wheels to the straight-ahead position. 2. Set the parking brake control. 3. Disconnect the battery ground cable. 4. Remove the bolt retaining the upper shaft assembly to lower shaft assembly. 5. Collapse the lower shaft approximately 51 mm (2 inches) to allow separation of the upper and lower shafts. 6. Remove the bolt retaining the lower shaft assembly U-joint to the steering gear input shaft. 7. Remove the lower shaft assembly from the steering gear. INSTALLATION 1. Position the steering gear and front wheels in the straight-ahead position. 2. Align the flat on the U-joint of the lower shaft assembly with the flat on the steering gear input shaft, and install the shaft on the steering gear. Install the retaining bolt and tighten. 3. Extend the lower shaft and insert a new bolt into the double Cardan joint. 4. Check the steering column for proper operation. 5. Reconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications TORQUE SPECIFICATIONS Steering Wheel Retaining Bolt ................................................................................................................................................... 31-44 Nm (23-32 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 7626 Steering Wheel: Service Precautions WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG VEHICLE AND WHEN HANDLING AN AIR BAG. - CARRY A LIVE AIR BAG WITH THE BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL RESULT IN A MINIMAL CHANCE OF INJURY. - PLACE A LIVE AIR BAG ON A BENCH OR OTHER SURFACE WITH THE COVER FACING UP. - AFTER DEPLOYMENT, THE AIR BAG SURFACE MAY CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING A DEPLOYED AIR BAG. - NEVER PROBE THE CONNECTORS ON THE AIR BAGS. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, CAUSING PERSONAL INJURY. - AIR BAG MODULES WITH DISCOLORED OR DAMAGED COVERS OR DEPLOYMENT DOORS MUST BE REPLACED, NOT REPAINTED. CAUTION: Do not remove the steering column, steering wheel, steering wheel pad horn switch and air bag module from the vehicle as an assembly unless the column is locked to prevent rotation. The lower end of the steering shaft should be wired to prevent the steering wheel from being rotated. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 7627 Steering Wheel: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG VEHICLE AND WHEN HANDLING AN AIR BAG. - CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING A DEPLOYED AIR BAG. - NEVER PROBE THE CONNECTORS ON THE AIR BAGS. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - AIR BAG MODULES WITH DISCOLORED OR DAMAGED COVERS OR DEPLOYMENT DOORS MUST BE REPLACED, NOT REPAINTED. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SYSTEM IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, THE SENSOR MUST BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: Make sure the wheels are in the straight-ahead position. 2. Remove the driver air bag module. 3. Remove the steering wheel bolt. 4. Use the 2-Jaw Puller to remove the steering wheel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 7628 CAUTION: Removing the steering wheel without using a puller can damage the column bearings. 5. Remove and discard the original steering wheel bolt. 6. Remove the steering wheel while routing the wires from the air bag sliding contact through the steering wheel. INSTALLATION 1. Follow the removal procedure in reverse order. 2. Connect the battery cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications TORQUE SPECIFICATIONS Castellated Nut, Tie Rod End To Drag Link ............................................................................................................................ 76-114 Nm (56-84 ft. lbs.) Castellated Nut, Tie Rod End To Spindle ................................................................................................................................ 76-114 Nm (56-84 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner Tie Rod End: Service and Repair Inner REMOVAL NOTE: Replace the steering tie rod if the ball stud is loose in the steering control ball stud socket or the rod is bent. Replace the front suspension steering ball stud dust seal if any nicks, cuts or tears are present. Do not attempt to straighten a bent rod. 1. Raise the vehicle on a hoist, with the wheels in the straight-ahead position. 2. Remove the tie rod end castellated nut. (1) Remove the cotter pin. (2) Remove the nut. 3. Using the Pitman Arm Puller, remove the ball stud from the steering sector shaft arm drag link. 4. Remove the tie rod. (1) Loosen the bolts on the tie rod adjusting sleeve clamp. (2) Count and record the number of turns required to remove the tie rod end from the tie rod adjusting sleeve clamp. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7635 1. Install the tie rod end. (1) Turn the tie rod end into the tie rod adjusting sleeve clamp with the same number of turns as required for removal. (2) Tighten the tie rod end adjusting sleeve clamp bolts. NOTE: The two bolts and nuts on the tie rod adjusting sleeve clamp for the tie rod end must be positioned within a limit of 45 degrees (±). The threaded ends of the bolts on the left tie rod end point toward the front of the vehicle. The threaded ends of the bolts on the right tie rod end face rearward. 2. Install the castle nut and a new cotter pin. NOTE: Make sure the ball stud is seated in the taper, to prevent rotation while tightening. 3. Check toe-in. Check clear vision. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7636 Tie Rod End: Service and Repair Outer REMOVAL 1. Raise and support the vehicle. 2. Remove the tie rod end castellated nut. (1) Remove the cotter pin. (2) Remove the nut. 3. Using the Pitman Arm Puller, remove the tie rod end ball stud from the front wheel spindle. 4. Remove the tie rod end. (1) Loosen the bolts on the tie rod adjusting sleeve clamp. (2) Count the number of turns required to remove the tie rod end from the tie rod adjusting sleeve clamp. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7637 1. Install the tie rod end. - Turn the tie rod end into the tie rod adjusting sleeve clamp approximately the same number of turns used to remove old tie rod end. This will provide an approximate toe-in setting. 2. Tighten the tie rod adjusting sleeve clamp. 3. Install the ball stud in the front wheel spindle, then tighten the castle nut. 4. Install a new cotter pin. 5. Check toe-in. Check clear vision. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7638 Tie Rod End: Service and Repair Replacement REMOVAL NOTE: Replace the ball stud if loose in the steering control bail stud socket or the tie rod end is bent. Replace the front suspension steering ball stud dust seal if any nicks, cuts or tears are present. Do not attempt to straighten a bent tie rod end. 1. Raise the vehicle on a hoist, with the wheels in the straight-ahead position. 2. Remove the tie rod end castle nut. (1) Remove the cotter pin. (2) Remove the nut. 3. Using the Pitman Arm Puller, remove the ball stud from the front wheel spindle. 4. Remove the tie rod end. (1) Loosen the nuts on the tie rod adjusting sleeve. (2) Count the number of turns while removing the tie rod end from the tie rod adjusting sleeve. 5. Remove the tie rod adjusting sleeve. Count the number of turns required to remove the tie rod adjusting sleeve clamp. INSTALLATION 1. Follow the removal procedure in reverse order. Make sure the adjuster clamps are in the correct position. NOTE: The two bolts and nuts on the tie rod adjusting sleeve clamp for the tie rod end must be positioned within a limit of 45 degrees (±). The threaded ends of the bolts on the left tie rod end point toward the front of the vehicle. The threaded ends on the right tie rod end face rearward. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7639 2. Tighten the tie rod adjusting sleeve. 3. Install the ball stud in the front wheel spindle, then tighten the castle nut. 4. Install a new cotter pin. 5. Check toe-in. 6. Check clear vision. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Page 7640 Special Tool(s) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Specifications Axle Beam: Specifications TORQUE SPECIFICATIONS Axle Pivot Nut (Tighten With Vehicle Weight On The Suspension) ........................................................................................................................................ 148-202 Nm (110-148 ft. lbs.) Axle-to-Radius Arm Nut .................................................................................................................................................... 255-345 Nm (188-254 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Axle Pivot Bushing Axle Beam: Service and Repair Axle Pivot Bushing REMOVAL 1. Remove the front coil spring for the affected front axle. 2. Remove the bolt and lower the pivot end of the front axle. NOTE: In order to obtain clearance for pivot bolt removal when servicing the RH front axle, it may be necessary to raise the LH side of the vehicle to relieve the weight on the suspension. 3. Using the Forcing Screw, Bushing Remover and Receiver Cup, remove the axle pivot bushing. INSTALLATION 1. Position the new pivot bushing - Position spacing washers, the Receiver Cup, Forcing Screw, Bushing Replacer, and the new pivot bushing on the front axle. CAUTION: The new pivot bushing must be free of grease, oil or other contamination. NOTE: The flanged end of the pivot bushing faces the front of the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Axle Pivot Bushing > Page 7647 2. Press the new pivot bushing into the front axle, leaving the specified clearance between the pivot bushing flange and the front axle. 3. Position the front axle, bolt and nut into the pivot bracket. Tighten the nut hand tight. 4. Install the front coil spring. 5. Lower the vehicle and, with the vehicle weight on the suspension, tighten the axle pivot nut. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Axle Pivot Bushing > Page 7648 Axle Beam: Service and Repair Front Axle Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the disc brake caliper and front disc brake hub and rotor assembly. 4. Remove the front disc brake rotor shield. 5. Remove the cotter pin and the castellated nut, using the Pitman Arm Puller disconnect the tie rod end. 6. Remove the cotter pin and the lower ball joint nut. Discard the cotter pin. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Axle Pivot Bushing > Page 7649 7. Remove the pinch bolt and the camber adjuster. 8. Remove the front wheel spindle. (1) Strike the lower end of the axle to loosen the ball joint. (2) Remove the front wheel spindle. CAUTION: To prevent damage to the ball joint seal and the ball joint socket, do not use a pickle fork-type remover to loosen the ball joints. 9. Remove the front coil spring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Axle Pivot Bushing > Page 7650 10. Remove the spring insulator. (1) Remove the radius arm-to-axle nut and bolt. (2) Remove the spring retainer and insulator. 11. Remove the radius arm. (1) Remove the nut. (2) Remove the washer and rear insulator. (3) Remove the radius arm from the bracket, and remove the spacer, insulator and washer. 12. Remove the pivot nut and bolt and remove the axle. NOTE: In order to obtain clearance for the pivot bolt removal when servicing the RH front axle, it may be necessary to raise the LH side of the vehicle to relieve the weight on the suspension. Installation 1. Inspect the pivot bushing for wear or damage. Replace as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Axle Pivot Bushing > Page 7651 2. Position the front axle into the pivot bracket and install the pivot bolt and nut hand-tight. 3. Inspect the radius arm insulators for wear or damage. Replace as necessary. 4. Install the radius arm. (1) Install the washer, insulator and spacer and pull the radius arm through the bracket. (2) Install the rear insulator, washer and nut and tighten hand-tight. 5. Install the spring insulator. (1) Install the spring retainer and insulator. (2) Install the radius arm-to-axle nut and bolts Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Axle Pivot Bushing > Page 7652 6. Tighten the radius arm-to-axle nut and bolt to specification. 7. Tighten the rear radius arm nut to specification. 8. Install the front coil spring. 9. Install the front wheel spindle in the front axle. (1) Position the front wheel spindle in the front axle. (2) Install the ball joint nut. (3) Install the new cotter pin. NOTE: Tighten the ball joint nut further, if necessary, in order to insert the new cotter pin. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Axle Pivot Bushing > Page 7653 10. Install the camber adjuster and pinch bolt. 11. Install the front disc brake rotor shield. 12. Install the front disc brake hub and rotor assembly and the disc brake caliper. 13. Using a new cotter pin, install the tie rod end in the front wheel spindle. 14. Install the tire and wheel assembly. 15. Lower the vehicle and, with the vehicle weight on the suspension, tighten the axle pivot bolt and nut to specification. 16. Perform front end alignment. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Page 7654 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Ball Joint - Proper Inspection Procedure Ball Joint: Technical Service Bulletins Ball Joint - Proper Inspection Procedure Article No. 99-14-1 07/12/99 BALL JOINT - PROPER INSPECTION PROCEDURE FORD: 1992-1999 ECONOLINE ISSUE A high number of ball joints are being replaced as the result of routine inspections or of complaints of tire wear and loose feelings in the steering system. Most of these parts are within specification and did not need replacement. There is a misunderstanding about how an Econoline/E-Series ball joint should feel and about how much movement is acceptable. ACTION Use proper inspection procedures and understand the acceptable amounts of movement within the ball joint. This action helps to avoid unnecessary replacement of ball joints at either customer or Ford Motor Company expense. Refer to the following Service Procedure for correct ball joint inspection details. SERVICE PROCEDURE NOTE DO NOT REPLACE SUSPENSION COMPONENTS THAT ARE WITHIN SPECIFICATION. Inspect Econoline/E-Series ball joints by lifting the vehicle and supporting the front axles on jack stands. Refer to the 1999 Econoline Workshop Manual, Section 100-02, for proper lifting techniques. Prior to performing any inspection of the ball joints, inspect the front wheel bearings for proper adjustment as follows: 1. Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. 2. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, adjust the front wheel bearing. For additional information, refer to the Workshop Manual, Section 206-03. NOTE SKIPPING INSPECTION OF THE WHEEL BEARINGS MAY RESULT IN FALSE READINGS ON BALL JOINT MOVEMENT. THIS MAY LEAD TO UNNECESSARY PARTS REPLACEMENT. LOWER BALL JOINT Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Ball Joint - Proper Inspection Procedure > Page 7659 1. Once wheel bearing inspection/adjustment is complete, have an assistant push and pull on the bottom of the tire (Figure 1). 2. Measure the amount of lateral lash AT THE BALL JOINT (Figure 1, View 1). Do Not Replace ball joint unless lateral lash movement is at or above 0.8 mm (1/32") AT THE BALL JOINT. Lateral lash of 0.8 mm (1/32") AT THE BALL JOINT will give a measurement of up to 4 mm (5/32") of movement at the bottom outer diameter of the tire (Figure 1, View 2). UPPER BALL JOINT 1. Once wheel bearing inspection/adjustment is complete, have an assistant push and pull on the top of the tire (Figure 2). 2. Measure the amount of lateral lash AT THE BALL JOINT (Figure 2, View 1). Do Not Replace ball joint unless lateral lash movement is at or above 0.8 mm (1/32") AT THE BALL JOINT. Lateral lash of 0.8 mm (1/32") AT THE BALL JOINT will give a measurement of up to 4 mm (5/32") of movement at the top outer diameter of the tire (Figure 2, View 2). VERTICAL END PLAY BOTH BALL JOINTS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Ball Joint - Proper Inspection Procedure > Page 7660 Econoline/E-Series ball joints have vertical end play. AT THE BALL JOINT (upper or lower), measure the amount of vertical end play. Do Not Replace the ball joint unless the vertical end play is at or above 2.3 mm (3/32") AT THE BALL JOINT (Figure 3). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 303000, 304000, 306000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid Ball Joint: Specifications Front Suspension Balljoint Inspection Job Aid Front Lower Balljoint Measurement ......................................................................................................... At lower balljoint between axle/twin I beam and spindle/knuckle Deflection ............................................................................................................................................. ........................................... 0-0.040 in (0-1.0mm) Reference Diagram ............................................................................................................................. ............................................................................. E Front Upper Balljoint Measurement ......................................................................................................... At upper balljoint between axle/twin I beam and spindle/knuckle Deflection ............................................................................................................................................. ........................................... 0-0.024 in (0-0.6mm) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7663 Reference Diagram ............................................................................................................................. ............................................................................. F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7664 Ball Joint: Specifications Ball Joint, Lower OPERATIONAL SPECIFICATIONS Ball Joint Radial Play - Maximum ....................................................................................................................................................... 0.8 mm (1/32 inch) TORQUE SPECIFICATIONS Lower Ball Joint Nut .......................................................................................................................................................... 149-203 Nm (110-150 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7665 Ball Joint: Specifications Ball Joint, Upper OPERATIONAL SPECIFICATIONS Ball Joint Radial Play - Maximum ....................................................................................................................................................... 0.8 mm (1/32 inch) TORQUE SPECIFICATIONS Pinch Bolt At Upper Ball Joint ................................................................................................................................................ 87-119 Nm (64-88 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection Ball Joint: Testing and Inspection Ball Joint Inspection 1. Raise and support the vehicle. 2. Prior to performing any inspection of the ball joints, inspect the front wheel bearings. 3. Position a safety stand beneath the front axle to be tested. 4. While an assistant pulls and pushes the bottom of the tire, observe the relative movement between the lower spindle arm and the front axle. Any movement at or exceeding the specification indicates a worn or damaged lower ball joint. Ball joint maximum radial play is 0.8 mm (1/32 in.). Replace as necessary. 5. While an assistant pulls and pushes the top of the tire, observe the relative movement between the upper spindle arm and the front axle. Movement at or exceeding the specification indicates a worn or damaged upper ball joint. Ball joint maximum radial play is 0.8 mm (1/32 in.). Replace the upper ball joint as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection > Page 7668 Ball Joint: Testing and Inspection Front Suspension Balljoint Inspection Job Aid Front Lower Balljoint Measurement ......................................................................................................... At lower balljoint between axle/twin I beam and spindle/knuckle Deflection ............................................................................................................................................. ........................................... 0-0.040 in (0-1.0mm) Reference Diagram ............................................................................................................................. ............................................................................. E Front Upper Balljoint Measurement ......................................................................................................... At upper balljoint between axle/twin I beam and spindle/knuckle Deflection ............................................................................................................................................. ........................................... 0-0.024 in (0-0.6mm) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection > Page 7669 Reference Diagram ............................................................................................................................. ............................................................................. F Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection > Page 7670 Ball Joint: Testing and Inspection Ball Joint, Lower 1. Raise and support the vehicle. 2. Prior to performing any inspection of the ball joints, inspect the front wheel bearings. 3. Position a safety stand beneath the front axle to be tested. 4. While an assistant pulls and pushes the bottom of the tire, observe the relative movement between the lower spindle arm and the front axle. Any movement at or exceeding the specification indicates a worn or damaged lower ball joint. Ball joint maximum radial play is 0.8 mm (1/32 in.). Replace as necessary. 5. While an assistant pulls and pushes the top of the tire, observe the relative movement between the upper spindle arm and the front axle. Movement at or exceeding the specification indicates a worn or damaged upper ball joint. Ball joint maximum radial play is 0.8 mm (1/32 in.). Replace the upper ball joint as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection > Page 7671 Ball Joint: Testing and Inspection Ball Joint, Upper 1. Raise and support the vehicle. 2. Prior to performing any inspection of the ball joints, inspect the front wheel bearings. 3. Position a safety stand beneath the front axle to be tested. 4. While an assistant pulls and pushes the bottom of the tire, observe the relative movement between the lower spindle arm and the front axle. Any movement at or exceeding the specification indicates a worn or damaged lower ball joint. Ball joint maximum radial play is 0.8 mm (1/32 in.). Replace as necessary. 5. While an assistant pulls and pushes the top of the tire, observe the relative movement between the upper spindle arm and the front axle. Movement at or exceeding the specification indicates a worn or damaged upper ball joint. Ball joint maximum radial play is 0.8 mm (1/32 in.). Replace the upper ball joint as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower Ball Joint: Service and Repair Ball Joint, Lower REMOVAL 1. Remove the front wheel spindle. 2. Position the front wheel spindle in a vise, and remove the snap ring from the lower ball joint. 3. Using the U-Joint Tool and appropriate Receiver Cup, remove the lower ball joint from the front wheel spindle. CAUTION: To avoid damage to the components, do not use heat to aid ball joint removal. 4. Using the U-Joint Tool and appropriate Receiver Cup, remove the upper ball joint. INSTALLATION 1. Using the U-Joint Tool and appropriate Ball Joint Adapter, install the upper ball joint. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 7674 CAUTION: To avoid damage to components, do not use heat to aid installation. NOTE: The upper ball joint must be installed first. 2. Using the U-Joint Tool and appropriate Ball Joint Adapter, install the lower ball joint. 3. Install the snap ring in the groove at the bottom of the ball joint. 4. Install the front wheel spindle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 7675 Ball Joint: Service and Repair Ball Joint, Upper REMOVAL 1. Remove the front wheel spindle. 2. Position the front wheel spindle in a vise, and remove the snap ring from the lower ball joint. 3. Using the U-Joint Tool and appropriate Receiver Cup, remove the lower ball joint from the front wheel spindle. CAUTION: To avoid damage to the components, do not use heat to aid ball joint removal. 4. Using the U-Joint Tool and appropriate Receiver Cup, remove the upper ball joint. INSTALLATION 1. Using the U-Joint Tool and appropriate Ball Joint Adapter, install the upper ball joint. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 7676 CAUTION: To avoid damage to components, do not use heat to aid installation. NOTE: The upper ball joint must be installed first. 2. Using the U-Joint Tool and appropriate Ball Joint Adapter, install the lower ball joint. 3. Install the snap ring in the groove at the bottom of the ball joint. 4. Install the front wheel spindle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Tools and Equipment > Ball Joint, Lower Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Tools and Equipment > Ball Joint, Lower > Page 7679 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest: > 01-11-9 > Jun > 01 > Frame - Creaking Noise/Cracked Cross-Member: Customer Interest Frame - Creaking Noise/Cracked Article No. 01-11-9 06/11/01 ^ FRAME - CRACKS IN RIGHT REAR # 1 CROSSMEMBER - VEHICLES WITH HIGH ODOMETER READING OR SEVERE SERVICE VEHICLES PRODUCED BEFORE 2/6/2001 ^ NOISE - "CREAKING" WHILE TURNING WHEEL OR DRIVING OVER UNEVEN SURFACES VEHICLES WITH HIGH ODOMETER READING OR SEVERE SERVICE - VEHICLES PRODUCED BEFORE 2/6/2001 FORD: 1997-2001 E SERIES, ECONOLINE This article is being republished in its entirety to update the model year coverage. ISSUE A "creaking" noise may be heard when turning wheel or driving over uneven surfaces on vehicles produced before 2/6/2001. This may be due to a crack on the right rear side of the # 1 crossmember. The crack may start from where the right rear attaching tab for the spring tower is located. ACTION Clean and weld the affected area including welding around the right rear attaching tab for the spring tower. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect right rear of the # 1 crossmember (Figure 1 - General Area) for any signs of a crack. 2. If a crack is NOT found, proceed with normal Noise/Vibration/Harshness (NVH) diagnostics. If any crack is found, begin by cleaning the area to be welded completely. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest: > 01-11-9 > Jun > 01 > Frame - Creaking Noise/Cracked > Page 7688 3. Drill holes at the end of the crack to prevent crack expansion. 4. V-grind the crack to ensure proper weld penetration. 5. Use clamps/jacks as necessary to align both sides of the crack. NOTE BE SURE THAT TEMPERATURE OF THE METAL DOES NOT EXCEED 760°C (1400°F) DURING WELDING. 6. Weld both sides of the affected areas where possible. 7. Weld around the edge of the right rear attaching tab for the spring tower to the # 1 crossmember of the frame (Figure 1, View A). DO NOT weld the rivet. 8. Clean off weld flash/scale and paint welded sections of the frame. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-14-11 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 305000, 390000, 702000, 702100 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-11-9 > Jun > 01 > Frame - Creaking Noise/Cracked Cross-Member: All Technical Service Bulletins Frame - Creaking Noise/Cracked Article No. 01-11-9 06/11/01 ^ FRAME - CRACKS IN RIGHT REAR # 1 CROSSMEMBER - VEHICLES WITH HIGH ODOMETER READING OR SEVERE SERVICE VEHICLES PRODUCED BEFORE 2/6/2001 ^ NOISE - "CREAKING" WHILE TURNING WHEEL OR DRIVING OVER UNEVEN SURFACES VEHICLES WITH HIGH ODOMETER READING OR SEVERE SERVICE - VEHICLES PRODUCED BEFORE 2/6/2001 FORD: 1997-2001 E SERIES, ECONOLINE This article is being republished in its entirety to update the model year coverage. ISSUE A "creaking" noise may be heard when turning wheel or driving over uneven surfaces on vehicles produced before 2/6/2001. This may be due to a crack on the right rear side of the # 1 crossmember. The crack may start from where the right rear attaching tab for the spring tower is located. ACTION Clean and weld the affected area including welding around the right rear attaching tab for the spring tower. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect right rear of the # 1 crossmember (Figure 1 - General Area) for any signs of a crack. 2. If a crack is NOT found, proceed with normal Noise/Vibration/Harshness (NVH) diagnostics. If any crack is found, begin by cleaning the area to be welded completely. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-11-9 > Jun > 01 > Frame - Creaking Noise/Cracked > Page 7694 3. Drill holes at the end of the crack to prevent crack expansion. 4. V-grind the crack to ensure proper weld penetration. 5. Use clamps/jacks as necessary to align both sides of the crack. NOTE BE SURE THAT TEMPERATURE OF THE METAL DOES NOT EXCEED 760°C (1400°F) DURING WELDING. 6. Weld both sides of the affected areas where possible. 7. Weld around the edge of the right rear attaching tab for the spring tower to the # 1 crossmember of the frame (Figure 1, View A). DO NOT weld the rivet. 8. Clean off weld flash/scale and paint welded sections of the frame. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-14-11 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 305000, 390000, 702000, 702100 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cross-Member: > 05-22-16 > Nov > 05 > Suspension - Spring Tower Flange Cracking Strut / Shock Tower: All Technical Service Bulletins Suspension - Spring Tower Flange Cracking TSB 05-22-16 11/14/05 SPRING TOWER WELD REPAIR AND REPLACEMENT PROCEDURE FORD: 1997-2006 E-350, E-450 This article supersedes TSB 05-1-1 to update the vehicle model years and service procedure. ISSUE Some higher-mileage E-350 and E-450 cutaway vans may exhibit cracks in the left or right spring tower flange. ACTION Certain front spring tower cracks can be repaired effectively by welding a reinforcement plate at the crack following the Service Procedure in this TSB. If the crack does not meet the criteria for this reinforcement plate repair, the spring tower should be replaced. SPRING TOWER CRACK REPAIR PROCEDURE NOTE SPRING TOWER CRACK REPAIR USING THE REINFORCEMENT PLATE WELD PROCEDURE SHOULD ONLY BE PERFORMED IF THE FOLLOWING CONDITIONS ARE MET. ^ The crack must exist in a location that is accessible and allows proper repair. Use the reinforcement plate procedure to repair areas where a welded reinforcement plate can be installed while maintaining adequate clearance to the spring and other components ^ The crack must have no branches. Flange edges shall be separated or misaligned by no more than 1/8" (3 mm) ^ LH front spring tower cracks must be no longer than 1.5" (38 mm) ^ RH front spring tower cracks must be no longer than 1.25" (32 mm) If any of the above conditions are not met, see the Spring Tower Replacement procedure at the end of this bulletin. EQUIPMENT REQUIRED ^ MIG welding equipment is required and should be capable of 150 amps or greater using ER70-6 welding wire ^ A straight or right angle die grinder is effective for repair preparation REINFORCEMENT PLATE REPAIR MATERIAL SPECIFICATION ^ Reinforcement plates used in this repair procedure can be made from low carbon steel of the correct grade and thickness, similar to the front spring tower. They should be roughly rectangular shape. Other shapes may be cut and used for improved fit to the affected area of the flange, or to provide improved reinforcement. Repairs to non-flat areas of the spring tower flange require reinforcement plates to be formed to fit the contour of the spring tower. In some cases, the service spring tower part may be suitable as a source for the reinforcement plate ^ The spring tower is made of low carbon steel (SAE J403, grade 1008-1010). Spring tower material thickness is approximately 0.19" (4.8 mm) ^ Reinforcement plate material thickness should be in the range of 0.18"- 0.23" (4.6-5.8 mm) Approximate reinforcement plate size should be 4" +/- 3/8" long, by 5/8" +/- 1/8" wide (102 +/- 10 mm long, by 16 mm +/- 3 mm wide) ^ Reinforcement plates should be uncoated, free of rust or oil, and have smooth edges and surfaces REPAIR PROCEDURE NOTE A REINFORCEMENT PLATE IS REQUIRED TO REPAIR EACH CRACK. 1. Disconnect the battery. Use precautions to protect vehicle and customer installed equipment from damage during welding. 2. Support the vehicle on a frame hoist. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cross-Member: > 05-22-16 > Nov > 05 > Suspension - Spring Tower Flange Cracking > Page 7700 3. Remove the front wheel assembly on the side to be repaired. 4. Loosen the front shock absorber at upper attachment, or disconnect the front shock at the lower attachment, to permit the axle to move down so the spring can be removed. Remove the front spring upper retainer and the front spring. Refer to the E-Series Workshop Manual. If required for inspection or repair access, also remove the shock from vehicle. 5. Cover the wheel end, brake rotor and brake hoses with a welding blanket to protect from grinding debris and weld spatter. 6. Clean or de-grease spring tower and ensure that all cracks have been identified. Prepare suitably sized reinforcement plates for the repair. 7. LH only, if necessary for access, remove the rear most steering gear bolt and apply tape over the hole to protect it from weld spatter. 8. Remove frame wax or E-coat from the spring tower in the areas to be welded, with a straight or right angle die grinder with a Scotch-Brite(TM) (or similar pad) and wax and grease remover. Include areas of the flange where the reinforcement plate will be welded to the spring tower. Also, clean up the back or inboard side of the flange in the area to be repaired. 9. Use a small burr tool to grind along the crack and form a U-groove for weld metal deposit. The U-groove should extend from the trimmed flange to approximately 3/8" (10 mm) beyond the visible end of the crack. No more than 1 mm of the original metal thickness should remain in the ground area at the "bottom" of the U-groove. 10. Use a 36 grit 3" grinding disk and chamfer any sharp edges along the U-groove, and grind the spring tower flange edge smooth 1" (25 mm) on either side of the crack location. 11. Using a MIG welder, fill the crack from its termination back toward the initiation point at the trim edge of the spring tower flange. 12. Cool the repair weld with an air blast and inspect. 13. Grind the weld flush with the original outboard surface of the spring tower. The recommended grinding direction for this operation is perpendicular to the direction of crack. 14. Check the reinforcement plate for proper fit-up to the repaired area. 15. If access to the flange edge is good, position and clamp the reinforcement plate on the spring tower flange so that the plate's edge is flush with the flange edge (butt joint edge). NOTE IF ACCESS TO THE FLANGE EDGE IS POOR, POSITION AND CLAMP THE REINFORCEMENT PLATE ON THE SPRING TOWER FLANGE SO THAT THE PLATE'S EDGE IS SLIGHTLY INSIDE THE FLANGE EDGE (LAP JOINT EDGE). 16. Begin by tack welding the reinforcement plate in place starting at the plate's edges farthest from the crack. Check MIG welder torch access for the weld pass, then make a weld along the inside edge of the reinforcement plate. Vertical down weld direction is preferred when possible. 17. Recheck for proper fit-up, adjust as required, and then make another weld pass along the outside edge of the reinforcement plate. A vertical down weld direction is preferred when possible. 18. Cool the welded area with an air blast and inspect. If required, grind smooth to remove excess weld material and/or stress concentrations. 19. Apply corrosion inhibiting paint, Motorcraft Low Temperature Anti-Corrosion Coating (PM-12-A), to the repair area. 20. Reassemble the vehicle and secure fasteners to the proper torques, as specified in the Workshop Manual. NOTE VERIFY THE "T" SHAPED END OF THE UPPER SPRING RETAINER IS PROPERLY ENGAGED AND SEATED IN THE SLOT AT THE TOP OF THE SPRING TOWER BEFORE THE FASTENER IS SECURED. NOTE LH SIDE ONLY - IF STEERING GEAR BOLT WAS REMOVED, REAPPLY THREAD ADHESIVE TO THE BOLT BEFORE IT IS INSTALLED AND TORQUED. SPRING TOWER REPLACEMENT Spring Towers can be replaced if the above conditions for Spring Tower Repair are not met. These parts are for installation by a skilled welder at an appropriate vehicle repair facility according to the general frame welding guidelines in Section 502 of the E-Series Workshop Manual. Refer to TSB 97-4-7 for replacement of the Spring Tower to #1 cross member rivet with a bolt. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cross-Member: > 05-22-16 > Nov > 05 > Suspension - Spring Tower Flange Cracking > Page 7701 NOTE IF THE HOLES AND MOUNTING FEATURES ON THE RIGHT HAND SIDE (RHS) SERVICE PART ONLY DO NOT LINE UP WITH THOSE ON THE ORIGINAL EQUIPMENT COMPONENTS, AND THE VEHICLE WAS BUILT FROM 1/19/2001 THROUGH 4/10/2001, THEN THE REPLACEMENT BOLT HOLE SHOULD BE DRILLED AS OUTLINED IN FIGURE 1. RHS SPRING TOWERS FOR VEHICLES BUILT PRIOR TO 1/19/2001 WILL REQUIRE DRILLING FOR THE RHS REPLACEMENT BOLT HOLE. RHS SPRING TOWERS FOR VEHICLES BUILT AFTER 4/10/2001 SHOULD NOT REQUIRE DRILLING FOR THE RHS REPLACEMENT BOLT HOLE. Parts Block WARRANTY STATUS: Information Only - Not Warrantable OASIS CODES: 304000 305000 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cross-Member: > 05-22-16 > Nov > 05 > Suspension - Spring Tower Flange Cracking > Page 7707 3. Remove the front wheel assembly on the side to be repaired. 4. Loosen the front shock absorber at upper attachment, or disconnect the front shock at the lower attachment, to permit the axle to move down so the spring can be removed. Remove the front spring upper retainer and the front spring. Refer to the E-Series Workshop Manual. If required for inspection or repair access, also remove the shock from vehicle. 5. Cover the wheel end, brake rotor and brake hoses with a welding blanket to protect from grinding debris and weld spatter. 6. Clean or de-grease spring tower and ensure that all cracks have been identified. Prepare suitably sized reinforcement plates for the repair. 7. LH only, if necessary for access, remove the rear most steering gear bolt and apply tape over the hole to protect it from weld spatter. 8. Remove frame wax or E-coat from the spring tower in the areas to be welded, with a straight or right angle die grinder with a Scotch-Brite(TM) (or similar pad) and wax and grease remover. Include areas of the flange where the reinforcement plate will be welded to the spring tower. Also, clean up the back or inboard side of the flange in the area to be repaired. 9. Use a small burr tool to grind along the crack and form a U-groove for weld metal deposit. The U-groove should extend from the trimmed flange to approximately 3/8" (10 mm) beyond the visible end of the crack. No more than 1 mm of the original metal thickness should remain in the ground area at the "bottom" of the U-groove. 10. Use a 36 grit 3" grinding disk and chamfer any sharp edges along the U-groove, and grind the spring tower flange edge smooth 1" (25 mm) on either side of the crack location. 11. Using a MIG welder, fill the crack from its termination back toward the initiation point at the trim edge of the spring tower flange. 12. Cool the repair weld with an air blast and inspect. 13. Grind the weld flush with the original outboard surface of the spring tower. The recommended grinding direction for this operation is perpendicular to the direction of crack. 14. Check the reinforcement plate for proper fit-up to the repaired area. 15. If access to the flange edge is good, position and clamp the reinforcement plate on the spring tower flange so that the plate's edge is flush with the flange edge (butt joint edge). NOTE IF ACCESS TO THE FLANGE EDGE IS POOR, POSITION AND CLAMP THE REINFORCEMENT PLATE ON THE SPRING TOWER FLANGE SO THAT THE PLATE'S EDGE IS SLIGHTLY INSIDE THE FLANGE EDGE (LAP JOINT EDGE). 16. Begin by tack welding the reinforcement plate in place starting at the plate's edges farthest from the crack. Check MIG welder torch access for the weld pass, then make a weld along the inside edge of the reinforcement plate. Vertical down weld direction is preferred when possible. 17. Recheck for proper fit-up, adjust as required, and then make another weld pass along the outside edge of the reinforcement plate. A vertical down weld direction is preferred when possible. 18. Cool the welded area with an air blast and inspect. If required, grind smooth to remove excess weld material and/or stress concentrations. 19. Apply corrosion inhibiting paint, Motorcraft Low Temperature Anti-Corrosion Coating (PM-12-A), to the repair area. 20. Reassemble the vehicle and secure fasteners to the proper torques, as specified in the Workshop Manual. NOTE VERIFY THE "T" SHAPED END OF THE UPPER SPRING RETAINER IS PROPERLY ENGAGED AND SEATED IN THE SLOT AT THE TOP OF THE SPRING TOWER BEFORE THE FASTENER IS SECURED. NOTE LH SIDE ONLY - IF STEERING GEAR BOLT WAS REMOVED, REAPPLY THREAD ADHESIVE TO THE BOLT BEFORE IT IS INSTALLED AND TORQUED. SPRING TOWER REPLACEMENT Spring Towers can be replaced if the above conditions for Spring Tower Repair are not met. These parts are for installation by a skilled welder at an appropriate vehicle repair facility according to the general frame welding guidelines in Section 502 of the E-Series Workshop Manual. Refer to TSB 97-4-7 for replacement of the Spring Tower to #1 cross member rivet with a bolt. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cross-Member: > 05-22-16 > Nov > 05 > Suspension - Spring Tower Flange Cracking > Page 7708 NOTE IF THE HOLES AND MOUNTING FEATURES ON THE RIGHT HAND SIDE (RHS) SERVICE PART ONLY DO NOT LINE UP WITH THOSE ON THE ORIGINAL EQUIPMENT COMPONENTS, AND THE VEHICLE WAS BUILT FROM 1/19/2001 THROUGH 4/10/2001, THEN THE REPLACEMENT BOLT HOLE SHOULD BE DRILLED AS OUTLINED IN FIGURE 1. RHS SPRING TOWERS FOR VEHICLES BUILT PRIOR TO 1/19/2001 WILL REQUIRE DRILLING FOR THE RHS REPLACEMENT BOLT HOLE. RHS SPRING TOWERS FOR VEHICLES BUILT AFTER 4/10/2001 SHOULD NOT REQUIRE DRILLING FOR THE RHS REPLACEMENT BOLT HOLE. Parts Block WARRANTY STATUS: Information Only - Not Warrantable OASIS CODES: 304000 305000 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Specifications Radius Arm: Specifications TORQUE SPECIFICATIONS Radius Arm-to Rear Bracket Nut ......................................................................................................................................... 113-153 Nm (84-112 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Specifications > Page 7712 Radius Arm: Service and Repair REMOVAL 1. Remove the front coil spring. 2. Remove the spring insulator. (1) Remove the radius arm-to-axle nut and bolt. (2) Remove the spring retainer and insulator. 3. Remove the radius arm. (1) Remove the nut. (2) Remove the washer and rear insulator. (3) Pull the radius arm from the bracket, and remove the spacer, insulator and washer. INSTALLATION 1. Inspect rubber parts for wear or damage. Replace as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Specifications > Page 7713 2. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair REMOVAL CAUTION: The steering column must be in the locked position, or the lower end of the column wired in such a way that the steering column does not rotate, resulting in damage to the air bag sliding contact. NOTE: Discard the upper intermediate shaft to steering column shaft bolt upon removal. Do not reuse; replace with new bolts. 1. Remove the bolt retaining the upper shaft assembly U-joint to the steering column center shaft. 2. Remove the shock absorber electronic steering sensor. (1) Disconnect the electrical connector. (2) Remove the screws. (3) Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. (1) Remove the steering column lower bearing spring. (2) Remove the sensor ring. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Page 7718 2. Install the shock absorber electronic steering sensor. (1) Position the shock absorber electronic steering sensor. (2) Install the screws. (3) Connect the electrical connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair Spindle: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the disc brake caliper and the front disc brake hub and rotor. 4. Remove the front disc brake rotor shield. 5. Disconnect the tie rod end using the Pitman Arm Puller. 6. Remove the cotter pin and the lower ball joint nut. - Discard the cotter pin. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > Page 7722 7. Remove the pinch bolt and the camber adjuster. 8. Remove the front wheel spindle. (1) Strike the lower end of the front axle to loosen the ball joint. (2) Remove the front wheel spindle. CAUTION: To prevent damage to the ball joint seal and the ball joint socket, do not use a pickle fork-type remover to loosen the ball joints. INSTALLATION 1. Install the front wheel spindle in the front axle. (1) Position the front wheel spindle in the front axle. (2) Install the ball joint nut. (3) Install a new cotter pin. NOTE: Tighten the ball joint nut further, if necessary, in order to insert the new cotter pin. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > Page 7723 2. Install the camber adjuster and pinch bolt. 3. Install the front disc brake rotor shield. 4. Install the front disc brake hub and rotor and the disc brake caliper. 5. Using a new cotter pin, install the tie rod end in the front wheel spindle. 6. Install the tire and wheel assembly. 7. Check the toe setting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > Page 7724 Special Tool(s) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair Stabilizer Bushing: Service and Repair REMOVAL 1. Remove the front stabilizer bar. 2. Remove the stabilizer bar bushing. (1) Position the Forcing Screw, Receiver Cup and Bushing Remover through the stabilizer bar bushing. (2) Press the stabilizer bar bushing out of the front axle. INSTALLATION 1. Install the stabilizer bar bushing. (1) Position the Forcing Screw, Receiver Cup, Installation Cup and stabilizer bar bushing on the front axle. (2) Press the stabilizer bar bushing into the front axle until seated. 2. Install the front stabilizer bar. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Page 7729 Stabilizer Bushing: Tools and Equipment Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 05-22-16 > Nov > 05 > Suspension - Spring Tower Flange Cracking Strut / Shock Tower: Customer Interest Suspension - Spring Tower Flange Cracking TSB 05-22-16 11/14/05 SPRING TOWER WELD REPAIR AND REPLACEMENT PROCEDURE FORD: 1997-2006 E-350, E-450 This article supersedes TSB 05-1-1 to update the vehicle model years and service procedure. ISSUE Some higher-mileage E-350 and E-450 cutaway vans may exhibit cracks in the left or right spring tower flange. ACTION Certain front spring tower cracks can be repaired effectively by welding a reinforcement plate at the crack following the Service Procedure in this TSB. If the crack does not meet the criteria for this reinforcement plate repair, the spring tower should be replaced. SPRING TOWER CRACK REPAIR PROCEDURE NOTE SPRING TOWER CRACK REPAIR USING THE REINFORCEMENT PLATE WELD PROCEDURE SHOULD ONLY BE PERFORMED IF THE FOLLOWING CONDITIONS ARE MET. ^ The crack must exist in a location that is accessible and allows proper repair. Use the reinforcement plate procedure to repair areas where a welded reinforcement plate can be installed while maintaining adequate clearance to the spring and other components ^ The crack must have no branches. Flange edges shall be separated or misaligned by no more than 1/8" (3 mm) ^ LH front spring tower cracks must be no longer than 1.5" (38 mm) ^ RH front spring tower cracks must be no longer than 1.25" (32 mm) If any of the above conditions are not met, see the Spring Tower Replacement procedure at the end of this bulletin. EQUIPMENT REQUIRED ^ MIG welding equipment is required and should be capable of 150 amps or greater using ER70-6 welding wire ^ A straight or right angle die grinder is effective for repair preparation REINFORCEMENT PLATE REPAIR MATERIAL SPECIFICATION ^ Reinforcement plates used in this repair procedure can be made from low carbon steel of the correct grade and thickness, similar to the front spring tower. They should be roughly rectangular shape. Other shapes may be cut and used for improved fit to the affected area of the flange, or to provide improved reinforcement. Repairs to non-flat areas of the spring tower flange require reinforcement plates to be formed to fit the contour of the spring tower. In some cases, the service spring tower part may be suitable as a source for the reinforcement plate ^ The spring tower is made of low carbon steel (SAE J403, grade 1008-1010). Spring tower material thickness is approximately 0.19" (4.8 mm) ^ Reinforcement plate material thickness should be in the range of 0.18"- 0.23" (4.6-5.8 mm) Approximate reinforcement plate size should be 4" +/- 3/8" long, by 5/8" +/- 1/8" wide (102 +/- 10 mm long, by 16 mm +/- 3 mm wide) ^ Reinforcement plates should be uncoated, free of rust or oil, and have smooth edges and surfaces REPAIR PROCEDURE NOTE A REINFORCEMENT PLATE IS REQUIRED TO REPAIR EACH CRACK. 1. Disconnect the battery. Use precautions to protect vehicle and customer installed equipment from damage during welding. 2. Support the vehicle on a frame hoist. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 05-22-16 > Nov > 05 > Suspension - Spring Tower Flange Cracking > Page 7738 3. Remove the front wheel assembly on the side to be repaired. 4. Loosen the front shock absorber at upper attachment, or disconnect the front shock at the lower attachment, to permit the axle to move down so the spring can be removed. Remove the front spring upper retainer and the front spring. Refer to the E-Series Workshop Manual. If required for inspection or repair access, also remove the shock from vehicle. 5. Cover the wheel end, brake rotor and brake hoses with a welding blanket to protect from grinding debris and weld spatter. 6. Clean or de-grease spring tower and ensure that all cracks have been identified. Prepare suitably sized reinforcement plates for the repair. 7. LH only, if necessary for access, remove the rear most steering gear bolt and apply tape over the hole to protect it from weld spatter. 8. Remove frame wax or E-coat from the spring tower in the areas to be welded, with a straight or right angle die grinder with a Scotch-Brite(TM) (or similar pad) and wax and grease remover. Include areas of the flange where the reinforcement plate will be welded to the spring tower. Also, clean up the back or inboard side of the flange in the area to be repaired. 9. Use a small burr tool to grind along the crack and form a U-groove for weld metal deposit. The U-groove should extend from the trimmed flange to approximately 3/8" (10 mm) beyond the visible end of the crack. No more than 1 mm of the original metal thickness should remain in the ground area at the "bottom" of the U-groove. 10. Use a 36 grit 3" grinding disk and chamfer any sharp edges along the U-groove, and grind the spring tower flange edge smooth 1" (25 mm) on either side of the crack location. 11. Using a MIG welder, fill the crack from its termination back toward the initiation point at the trim edge of the spring tower flange. 12. Cool the repair weld with an air blast and inspect. 13. Grind the weld flush with the original outboard surface of the spring tower. The recommended grinding direction for this operation is perpendicular to the direction of crack. 14. Check the reinforcement plate for proper fit-up to the repaired area. 15. If access to the flange edge is good, position and clamp the reinforcement plate on the spring tower flange so that the plate's edge is flush with the flange edge (butt joint edge). NOTE IF ACCESS TO THE FLANGE EDGE IS POOR, POSITION AND CLAMP THE REINFORCEMENT PLATE ON THE SPRING TOWER FLANGE SO THAT THE PLATE'S EDGE IS SLIGHTLY INSIDE THE FLANGE EDGE (LAP JOINT EDGE). 16. Begin by tack welding the reinforcement plate in place starting at the plate's edges farthest from the crack. Check MIG welder torch access for the weld pass, then make a weld along the inside edge of the reinforcement plate. Vertical down weld direction is preferred when possible. 17. Recheck for proper fit-up, adjust as required, and then make another weld pass along the outside edge of the reinforcement plate. A vertical down weld direction is preferred when possible. 18. Cool the welded area with an air blast and inspect. If required, grind smooth to remove excess weld material and/or stress concentrations. 19. Apply corrosion inhibiting paint, Motorcraft Low Temperature Anti-Corrosion Coating (PM-12-A), to the repair area. 20. Reassemble the vehicle and secure fasteners to the proper torques, as specified in the Workshop Manual. NOTE VERIFY THE "T" SHAPED END OF THE UPPER SPRING RETAINER IS PROPERLY ENGAGED AND SEATED IN THE SLOT AT THE TOP OF THE SPRING TOWER BEFORE THE FASTENER IS SECURED. NOTE LH SIDE ONLY - IF STEERING GEAR BOLT WAS REMOVED, REAPPLY THREAD ADHESIVE TO THE BOLT BEFORE IT IS INSTALLED AND TORQUED. SPRING TOWER REPLACEMENT Spring Towers can be replaced if the above conditions for Spring Tower Repair are not met. These parts are for installation by a skilled welder at an appropriate vehicle repair facility according to the general frame welding guidelines in Section 502 of the E-Series Workshop Manual. Refer to TSB 97-4-7 for replacement of the Spring Tower to #1 cross member rivet with a bolt. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 05-22-16 > Nov > 05 > Suspension - Spring Tower Flange Cracking > Page 7739 NOTE IF THE HOLES AND MOUNTING FEATURES ON THE RIGHT HAND SIDE (RHS) SERVICE PART ONLY DO NOT LINE UP WITH THOSE ON THE ORIGINAL EQUIPMENT COMPONENTS, AND THE VEHICLE WAS BUILT FROM 1/19/2001 THROUGH 4/10/2001, THEN THE REPLACEMENT BOLT HOLE SHOULD BE DRILLED AS OUTLINED IN FIGURE 1. RHS SPRING TOWERS FOR VEHICLES BUILT PRIOR TO 1/19/2001 WILL REQUIRE DRILLING FOR THE RHS REPLACEMENT BOLT HOLE. RHS SPRING TOWERS FOR VEHICLES BUILT AFTER 4/10/2001 SHOULD NOT REQUIRE DRILLING FOR THE RHS REPLACEMENT BOLT HOLE. Parts Block WARRANTY STATUS: Information Only - Not Warrantable OASIS CODES: 304000 305000 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 05-22-16 > Nov > 05 > Suspension Spring Tower Flange Cracking Strut / Shock Tower: All Technical Service Bulletins Suspension - Spring Tower Flange Cracking TSB 05-22-16 11/14/05 SPRING TOWER WELD REPAIR AND REPLACEMENT PROCEDURE FORD: 1997-2006 E-350, E-450 This article supersedes TSB 05-1-1 to update the vehicle model years and service procedure. ISSUE Some higher-mileage E-350 and E-450 cutaway vans may exhibit cracks in the left or right spring tower flange. ACTION Certain front spring tower cracks can be repaired effectively by welding a reinforcement plate at the crack following the Service Procedure in this TSB. If the crack does not meet the criteria for this reinforcement plate repair, the spring tower should be replaced. SPRING TOWER CRACK REPAIR PROCEDURE NOTE SPRING TOWER CRACK REPAIR USING THE REINFORCEMENT PLATE WELD PROCEDURE SHOULD ONLY BE PERFORMED IF THE FOLLOWING CONDITIONS ARE MET. ^ The crack must exist in a location that is accessible and allows proper repair. Use the reinforcement plate procedure to repair areas where a welded reinforcement plate can be installed while maintaining adequate clearance to the spring and other components ^ The crack must have no branches. Flange edges shall be separated or misaligned by no more than 1/8" (3 mm) ^ LH front spring tower cracks must be no longer than 1.5" (38 mm) ^ RH front spring tower cracks must be no longer than 1.25" (32 mm) If any of the above conditions are not met, see the Spring Tower Replacement procedure at the end of this bulletin. EQUIPMENT REQUIRED ^ MIG welding equipment is required and should be capable of 150 amps or greater using ER70-6 welding wire ^ A straight or right angle die grinder is effective for repair preparation REINFORCEMENT PLATE REPAIR MATERIAL SPECIFICATION ^ Reinforcement plates used in this repair procedure can be made from low carbon steel of the correct grade and thickness, similar to the front spring tower. They should be roughly rectangular shape. Other shapes may be cut and used for improved fit to the affected area of the flange, or to provide improved reinforcement. Repairs to non-flat areas of the spring tower flange require reinforcement plates to be formed to fit the contour of the spring tower. In some cases, the service spring tower part may be suitable as a source for the reinforcement plate ^ The spring tower is made of low carbon steel (SAE J403, grade 1008-1010). Spring tower material thickness is approximately 0.19" (4.8 mm) ^ Reinforcement plate material thickness should be in the range of 0.18"- 0.23" (4.6-5.8 mm) Approximate reinforcement plate size should be 4" +/- 3/8" long, by 5/8" +/- 1/8" wide (102 +/- 10 mm long, by 16 mm +/- 3 mm wide) ^ Reinforcement plates should be uncoated, free of rust or oil, and have smooth edges and surfaces REPAIR PROCEDURE NOTE A REINFORCEMENT PLATE IS REQUIRED TO REPAIR EACH CRACK. 1. Disconnect the battery. Use precautions to protect vehicle and customer installed equipment from damage during welding. 2. Support the vehicle on a frame hoist. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 05-22-16 > Nov > 05 > Suspension Spring Tower Flange Cracking > Page 7745 3. Remove the front wheel assembly on the side to be repaired. 4. Loosen the front shock absorber at upper attachment, or disconnect the front shock at the lower attachment, to permit the axle to move down so the spring can be removed. Remove the front spring upper retainer and the front spring. Refer to the E-Series Workshop Manual. If required for inspection or repair access, also remove the shock from vehicle. 5. Cover the wheel end, brake rotor and brake hoses with a welding blanket to protect from grinding debris and weld spatter. 6. Clean or de-grease spring tower and ensure that all cracks have been identified. Prepare suitably sized reinforcement plates for the repair. 7. LH only, if necessary for access, remove the rear most steering gear bolt and apply tape over the hole to protect it from weld spatter. 8. Remove frame wax or E-coat from the spring tower in the areas to be welded, with a straight or right angle die grinder with a Scotch-Brite(TM) (or similar pad) and wax and grease remover. Include areas of the flange where the reinforcement plate will be welded to the spring tower. Also, clean up the back or inboard side of the flange in the area to be repaired. 9. Use a small burr tool to grind along the crack and form a U-groove for weld metal deposit. The U-groove should extend from the trimmed flange to approximately 3/8" (10 mm) beyond the visible end of the crack. No more than 1 mm of the original metal thickness should remain in the ground area at the "bottom" of the U-groove. 10. Use a 36 grit 3" grinding disk and chamfer any sharp edges along the U-groove, and grind the spring tower flange edge smooth 1" (25 mm) on either side of the crack location. 11. Using a MIG welder, fill the crack from its termination back toward the initiation point at the trim edge of the spring tower flange. 12. Cool the repair weld with an air blast and inspect. 13. Grind the weld flush with the original outboard surface of the spring tower. The recommended grinding direction for this operation is perpendicular to the direction of crack. 14. Check the reinforcement plate for proper fit-up to the repaired area. 15. If access to the flange edge is good, position and clamp the reinforcement plate on the spring tower flange so that the plate's edge is flush with the flange edge (butt joint edge). NOTE IF ACCESS TO THE FLANGE EDGE IS POOR, POSITION AND CLAMP THE REINFORCEMENT PLATE ON THE SPRING TOWER FLANGE SO THAT THE PLATE'S EDGE IS SLIGHTLY INSIDE THE FLANGE EDGE (LAP JOINT EDGE). 16. Begin by tack welding the reinforcement plate in place starting at the plate's edges farthest from the crack. Check MIG welder torch access for the weld pass, then make a weld along the inside edge of the reinforcement plate. Vertical down weld direction is preferred when possible. 17. Recheck for proper fit-up, adjust as required, and then make another weld pass along the outside edge of the reinforcement plate. A vertical down weld direction is preferred when possible. 18. Cool the welded area with an air blast and inspect. If required, grind smooth to remove excess weld material and/or stress concentrations. 19. Apply corrosion inhibiting paint, Motorcraft Low Temperature Anti-Corrosion Coating (PM-12-A), to the repair area. 20. Reassemble the vehicle and secure fasteners to the proper torques, as specified in the Workshop Manual. NOTE VERIFY THE "T" SHAPED END OF THE UPPER SPRING RETAINER IS PROPERLY ENGAGED AND SEATED IN THE SLOT AT THE TOP OF THE SPRING TOWER BEFORE THE FASTENER IS SECURED. NOTE LH SIDE ONLY - IF STEERING GEAR BOLT WAS REMOVED, REAPPLY THREAD ADHESIVE TO THE BOLT BEFORE IT IS INSTALLED AND TORQUED. SPRING TOWER REPLACEMENT Spring Towers can be replaced if the above conditions for Spring Tower Repair are not met. These parts are for installation by a skilled welder at an appropriate vehicle repair facility according to the general frame welding guidelines in Section 502 of the E-Series Workshop Manual. Refer to TSB 97-4-7 for replacement of the Spring Tower to #1 cross member rivet with a bolt. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 05-22-16 > Nov > 05 > Suspension Spring Tower Flange Cracking > Page 7746 NOTE IF THE HOLES AND MOUNTING FEATURES ON THE RIGHT HAND SIDE (RHS) SERVICE PART ONLY DO NOT LINE UP WITH THOSE ON THE ORIGINAL EQUIPMENT COMPONENTS, AND THE VEHICLE WAS BUILT FROM 1/19/2001 THROUGH 4/10/2001, THEN THE REPLACEMENT BOLT HOLE SHOULD BE DRILLED AS OUTLINED IN FIGURE 1. RHS SPRING TOWERS FOR VEHICLES BUILT PRIOR TO 1/19/2001 WILL REQUIRE DRILLING FOR THE RHS REPLACEMENT BOLT HOLE. RHS SPRING TOWERS FOR VEHICLES BUILT AFTER 4/10/2001 SHOULD NOT REQUIRE DRILLING FOR THE RHS REPLACEMENT BOLT HOLE. Parts Block WARRANTY STATUS: Information Only - Not Warrantable OASIS CODES: 304000 305000 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Front Suspension Spring ( Coil / Leaf ): Specifications Front TORQUE SPECIFICATIONS Front Spring Upper Retainer Bolt .............................................................................................................................................. 25-35 Nm (19-26 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Front > Page 7751 Suspension Spring ( Coil / Leaf ): Specifications Leaf Spring TORQUE SPECIFICATIONS Leaf Spring-to-Axle U-Bolt Nut ........................................................................................................................................ 149-203 Nm (110-150 ft. lbs.) Leaf Spring-to-Front Bracket Bolt ..................................................................................................................................... 325-393 Nm (240-289 ft. lbs.) Leaf Spring-to-Rear Shackle Nut & Bolt ................................................................................................................................. 77-103 Nm (57-76 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Page 7752 Suspension Spring ( Coil / Leaf ): Description and Operation Semi-elliptic, leaf-type rear springs are used for the rear suspension. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear Leaf Spring Suspension Spring ( Coil / Leaf ): Service and Repair Rear Leaf Spring REMOVAL 1. Remove the wheel and tire assembly. 2. Use Hi-Lift Jack to support the rear axle. 3. Disconnect the lower end of the rear shock absorber. 4. Separate the rear spring from the rear axle. (1) Remove the nuts. (2) Remove the U-bolts. (3) Remove the rear spring plate. 5. Remove the rear spring. (1) Remove the bolt and nut. (2) Remove the bolt and nut. (3) Remove the rear spring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear Leaf Spring > Page 7755 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear Leaf Spring > Page 7756 Suspension Spring ( Coil / Leaf ): Service and Repair Coil Spring REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the front stabilizer bar. 4. Use a suitable jack to support the affected front axle. CAUTION: The axle must be supported throughout the procedure to prevent strain on the front brake hose. If necessary, remove the disc brake caliper for additional clearance. 5. Disconnect the shock absorber from the radius arm. (1) Remove the lower shock absorber nut. (2) Disconnect the lower end of the shock absorber. 6. Remove the bolt and the upper spring retainer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear Leaf Spring > Page 7757 7. Lower the jack supporting the front axle and remove the coil spring. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Page 7758 Spring Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications TORQUE SPECIFICATIONS Front Shock Lower Nut .............................................................................................................................................................. 68-92 Nm (50-68 ft. lbs.) Front Shock Upper Nut .............................................................................................................................................................. 34-47 Nm (25-35 ft. lbs.) Rear Shock Lower Mount Nut & Bolt ....................................................................................................................................... 68-92 Nm (51-67 ft. lbs.) Rear Shock Upper Mount Nut .................................................................................................................................................... 35-45 Nm (26-33 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 7762 Suspension Strut / Shock Absorber: Description and Operation The rear shock absorbers provide the necessary suspension dampening control. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 7763 Suspension Strut / Shock Absorber: Testing and Inspection 1. Raise and support the vehicle. WARNING: THE LOW PRESSURE GAS SHOCK ABSORBERS ARE CHARGED WITH NITROGEN GAS TO 931 KPA (13S PSI) FOR 1-3/16 INCH BORE, AND 1034 KPA (150 PSI) FOR 1-3/8 INCH BORE. DO NOT ATTEMPT TO OPEN, PUNCTURE, OR APPLY HEAT TO THE SHOCK ABSORBERS. 2. Inspect for evidence of fluid leakage. - Leakage is a condition in which the shock absorber body is covered with oil. In severe cases there may be oil dripping from the shock. - Weepage is a light film of oil on the shock absorber piston rod and is a result of proper shock lubrication. Weepage is a condition in which a thin film of oil is deposited on the upper portion of the shock body and is normally noticed due to the collection of dust in this area. 3. Inspect for damaged or worn shock absorber insulators. 4. Disconnect the lower end of the shock absorber. 5. Inspect the shock for proper operation. (1) Compress and extend the shock absorber as fast as possible, using as much travel as possible. (2) Inspect for the following abnormal conditions: - A lag or skip occurring during mid-stroke when the shock absorber is properly installed and primed. - Any seizing during the shaft full travel, except at either end of the travel. - Any noise, other than a faint swish, such as a clicking noise upon fast stroke reversal. - Any lateral motion of the piston rod in relation to the body with the shock absorber fully extended. 6. Replace any unserviceable shock absorbers or shock absorber insulators. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications Suspension Travel Bumper: Specifications TORQUE SPECIFICATIONS Front Jounce Bumper Screw ...................................................................................................................................................... 25-35 Nm (19-26 ft. lbs.) Rear Jounce Bumper To Frame Nut ........................................................................................................................................... 35-45 Nm (26-33 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications > Page 7767 Suspension Travel Bumper: Description and Operation The rear axle bumpers are used to prevent metal-to-metal contact between the rear axle and the frame. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7772 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7773 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7774 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7775 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7776 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7777 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7778 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7779 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7780 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7781 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7782 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7783 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7784 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7785 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7786 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7787 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7788 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7789 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7790 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7791 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7792 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7793 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7794 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7795 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7796 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7797 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7798 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7799 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7800 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7801 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7802 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7803 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7804 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7805 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7806 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7807 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7808 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7809 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7810 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7811 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7812 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7813 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7814 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7815 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7816 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7817 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7818 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7819 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7820 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7821 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7822 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7823 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7824 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7825 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7826 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7827 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7828 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7829 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7830 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7831 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7832 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7833 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7834 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7835 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7836 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7837 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7838 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7839 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7840 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7841 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7842 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7843 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7844 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7845 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7846 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7847 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7848 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7849 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7850 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7851 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7852 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7853 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7854 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7855 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7856 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7857 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7858 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7859 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7860 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7861 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7862 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7863 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7864 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7865 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7866 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Front Wheel Bearing: Specifications Front Lubricate the front wheel bearings. Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Front > Page 7869 Wheel Bearing: Specifications Rear Dana Semi-Floating Axle Lubricate the cavity between the lips of the axle shaft oil seal and the rear wheel bearing with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Ford Axles Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 7870 Wheel Bearing: Description and Operation Part 1 Of 2 Part 2 Of 2 SINGLE REAR WHEEL, E-350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 7871 DUAL REAR WHEEL, E-350 WHEEL HUBS AND BEARINGS The rear hub is supported or floats on the axle spindle on two opposed tapered roller bearings. The rear hub is retained on the spindle by a ratcheting nut that is tabbed to a slot on the spindle. The brake drum is mounted to the rear hub. A seal is installed inboard of the inner rear wheel bearing to keep the rear axle and wheel bearing lubricant from the brake components. The full-floating rear axles on E-350 vehicles have brake drums mounted outboard of the rear hub, permitting brake drum removal for brake inspection without the need to remove the rear hub. The E-Super Duty full-floating axle has rear disc brakes. The rear disc brake rotor is mounted to the rear hub. The rear wheel bearings are packed with a lithium-base grease, Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B, to provide initial lubrication until axle lubricant flows into the rear hubs and rear wheel bearing inner cone and rollers during vehicle operation. Vehicles equipped with Dual Rear Wheel (DRW) rear axles have the wheels attached to the brake drum on the E-350 vehicles or rear hub on E-Super Duty vehicles. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 7872 Wheel Bearing: Testing and Inspection 1. Raise the vehicle until the tire is off the floor. 2. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, adjust the front wheel bearings. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle Wheel Bearing: Service and Repair Dana Semi-Floating Axle Special Tools Special Tools REMOVAL 1. Remove the axle shaft. 2. Remove and discard the axle shaft oil seal from the axle tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 7875 NOTE: If only the seal needs to be replaced, it can be pried out of the tube bore. Use care to avoid damaging the seal bore. NOTE: The axle shaft oil seal can be removed with the rear wheel bearing as a unit. 3. Remove the rear wheel bearing. 1. Install the Front Hub Remover/Replacer, the Hub Remover Adapters and the Rear Axle Bearing Remover. 2. Pull the rear rear wheel bearing from the axle tube. WARNING: WEAR SAFETY GLASSES WHEN REMOVING THE REAR WHEEL BEARING. 4. Clean and inspect the rear wheel bearing bore. - Wipe the bore with emery cloth to ensure a smooth surface. - Clean out the bore with a standard metal-cleaning solvent. Wipe this area clean, making sure it is free of dirt or any other contaminants. NOTE: The rear wheel bearing bore must be free from nicks and burrs. If the bore has burrs or spalled areas and a new rear wheel bearing is installed, early failure can result. INSTALLATION 1. Coat the rear wheel bearing with differential lubricant for easier assembly and to prevent possible scoring of the tube bore. 2. Using the Front Hub Remover/Replacer, Hub Remover Adapters, Step Plate and the Rear Axle Bearing Replacer, install the rear rear wheel bearing. NOTE: During bearing installation, make sure the rear wheel bearing is not cocked in the bore. NOTE: Install the rear wheel bearing, with identification numbers on the rear wheel bearing facing out. 3. Using the Front Hub Remover/Replacer, the Hub Remover Adapters, the Step Plate and the Rear Axle Seal Replacer, install a new axle shaft oil Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 7876 seal. An alternate method of installing the axle shaft oil seal is with the Rear Axle Seal Replacer and Drive Handle. NOTE: Make sure the oil seal is not cocked in the bore during installation. 4. Lubricate the cavity between the lips of the axle shaft oil seal and the rear wheel bearing with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 5. Install the axle shaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 7877 Wheel Bearing: Service and Repair Ford 8.8 Inch Ring Gear Special Tools REMOVAL 1. Remove the axle shaft. 2. Use Impact Slide Hammer and Rear Axle Bearing Remover to remove the rear axle bearing and inner wheel bearing oil seal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 7878 NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged. INSTALLATION 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use Axle Tube Bearing Replacer with Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-l-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Use Axle Tube Seal Replacer with Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shaft. 9.75 Inch Ring Gear Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 7879 Special Tools REMOVAL 1. Remove the axle shaft. 2. Use the Impact Slide Hammer and the Axle Wheel Bearing Puller to remove the rear wheel bearing and inner wheel bearing oil seal. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged. INSTALLATION 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use the Axle Wheel Bearing Replacer with the Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 7880 4. Use the Axle Seat Replacer with the Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub Nut ............................................................................................................................................... ......................................... 88-102 Nm (65-75 ft. lbs.) (Back off 90 degrees, then retighten) ......................................................................................................................................... 20-27 Nm (15-20 ft. lbs.) Maximum Hub Rotating [1] .................................................................................................................. ............................................... 2.3 Nm (20 inch lbs.) [1] Final adjustment is 0 mm (0 inch) end play. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions CAUTION: - Damage to the suspension or steering linkage system components may occur when positioning the hoist adapters. The front adapter pads should be positioned carefully to ensure maximum contact under the center of the lower suspension arms or spring supports as near the wheels as practical. The rear suspension hoist adapters (forks) should be placed under the spring mounting pads or the rear axle housing tubes, but the adapters must not interfere with the shock absorber mounting brackets or the stabilizer bar mounting brackets. - When raising a vehicle on a twin post hoist, care should be taken to position the vehicle so that the hoisting adapters (forks) do not damage the axle housing cover or contact the rear stabilizer bar or brackets. - For proper wrecker towing procedures, refer to the vehicle Owner Guide. Improper towing of a vehicle can result in transmission damage. Always follow the outlined towing procedures. Refer to the hoist manufacturer's operating manual for proper lifting instructions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles Vehicle Lifting: Service and Repair Cutaway and Cargo Vehicles Frame - Left Front Frame - Right Front Frame - Left Rear Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles > Page 7891 Vehicle Lifting: Service and Repair Drive-On Hoist To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first checking for possible interference between the upright flanges of the hoist rails and the underbody. Should there be interference, the hoist flanges should be modified as necessary and the approach ramps built up to provide the necessary clearance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles > Page 7892 Vehicle Lifting: Service and Repair Frame Contact Hoist Adapters may be necessary to clear any vehicle components (front and rear) to lift the vehicle safely. This will provide enough clearance to prevent damaging the lower body. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles > Page 7893 Vehicle Lifting: Service and Repair Lifting Precautions CAUTION: - Damage to the suspension or steering linkage system components may occur when positioning the hoist adapters. The front adapter pads should be positioned carefully to ensure maximum contact under the center of the lower suspension arms or spring supports as near the wheels as practical. The rear suspension hoist adapters (forks) should be placed under the spring mounting pads or the rear axle housing tubes, but the adapters must not interfere with the shock absorber mounting brackets or the stabilizer bar mounting brackets. - When raising a vehicle on a twin post hoist, care should be taken to position the vehicle so that the hoisting adapters (forks) do not damage the axle housing cover or contact the rear stabilizer bar or brackets. - For proper wrecker towing procedures, refer to the vehicle Owner Guide. Improper towing of a vehicle can result in transmission damage. Always follow the outlined towing procedures. Refer to the hoist manufacturer's operating manual for proper lifting instructions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles > Page 7894 Vehicle Lifting: Service and Repair Cutaway and Cargo Vehicles Frame - Left Front Frame - Right Front Frame - Left Rear Drive-On Hoist To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first checking for possible interference between the upright flanges of the hoist rails and the underbody. Should there be interference, the hoist flanges should be modified as necessary and the approach ramps built up to provide the necessary clearance. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Cutaway and Cargo Vehicles > Page 7895 Frame Contact Hoist Adapters may be necessary to clear any vehicle components (front and rear) to lift the vehicle safely. This will provide enough clearance to prevent damaging the lower body. Lifting Precautions CAUTION: - Damage to the suspension or steering linkage system components may occur when positioning the hoist adapters. The front adapter pads should be positioned carefully to ensure maximum contact under the center of the lower suspension arms or spring supports as near the wheels as practical. The rear suspension hoist adapters (forks) should be placed under the spring mounting pads or the rear axle housing tubes, but the adapters must not interfere with the shock absorber mounting brackets or the stabilizer bar mounting brackets. - When raising a vehicle on a twin post hoist, care should be taken to position the vehicle so that the hoisting adapters (forks) do not damage the axle housing cover or contact the rear stabilizer bar or brackets. - For proper wrecker towing procedures, refer to the vehicle Owner Guide. Improper towing of a vehicle can result in transmission damage. Always follow the outlined towing procedures. Refer to the hoist manufacturer's operating manual for proper lifting instructions. Single Post Hoist Adapters may be necessary to clear any vehicle components (front and rear) to lift the vehicle safely. This will provide enough clearance to prevent damaging the lower body. Twin Post Hoist Damage to the suspension or steering linkage system components may occur when positioning the hoist adapters. The front adapter pads should be positioned carefully to ensure maximum contact under the center of the lower suspension arms or spring supports as near the wheels as practical. The rear suspension hoist adapters (forks) should be placed under the spring mounting pads or the rear axle housing tubes, but the adapters must not interfere with the shock absorber mounting brackets or the stabilizer bar mounting brackets. CAUTION: When raising a vehicle on a twin-post hoist, care should be taken to position the vehicle so that the hoisting adapters (forks) do not damage the axle housing cover or contact the rear stabilizer bar or brackets. Adapters may be necessary to clear any vehicle components (front and rear) to lift the vehicle safely. This will provide enough clearance to prevent damaging the lower body. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7900 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7901 Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7902 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7903 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7904 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7905 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7906 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7907 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7908 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7909 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7910 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7911 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7912 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7913 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7914 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7915 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7916 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7917 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7918 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7919 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7920 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7921 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7922 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7923 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7924 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7925 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7926 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7927 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7928 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7929 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7930 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7931 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7932 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7933 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7934 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7935 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7936 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7937 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7938 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7939 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7940 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7941 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7942 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7943 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7944 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7945 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7946 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7947 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7948 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7949 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7950 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7951 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7952 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7953 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7954 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7955 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7956 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7957 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7958 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7959 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7960 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7961 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7962 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7963 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7964 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7965 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7966 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7967 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7968 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7969 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7970 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7971 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7972 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7973 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7974 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7975 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7976 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7977 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7978 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7979 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7980 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7981 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7982 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7983 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7984 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7985 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7986 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7987 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7988 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7989 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7990 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7991 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7992 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7993 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7994 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7995 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7996 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 7997 Tires: Specifications Max. Radial Runout Aluminum ............................................................................................................................................. ..................................... 1.27 mm (0.050 inch) Steel ........................................................................... ................................................................................................................ 1.27 mm (0.050 inch) Max. Lateral Runout Aluminum ............................................................................................................................................. ..................................... 1.27 mm (0.050 inch) Steel ........................................................................... ................................................................................................................ 1.27 mm (0.050 inch) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service Precautions > Customer Safety Information Tires: Customer Safety Information WARNING: - THE TIRE AND WHEEL MUST ALWAYS BE PROPERLY MATCHED. IT IS VERY IMPORTANT TO DETERMINE THE SIZE OF EACH COMPONENT BEFORE ANY ASSEMBLY OPERATIONS COMMENCE. FAILURE TO ADHERE TO THESE INSTRUCTIONS CAN RESULT IN AN EXPLOSIVE SEPARATION AND CAUSE SERIOUS BODILY INJURY OR DEATH. - AFTERMARKET WHEEL ASSEMBLIES MAY NOT BE COMPATIBLE WITH THE VEHICLE. USE OF INCOMPATIBLE WHEEL ASSEMBLIES CAN RESULT IN EQUIPMENT FAILURE AND POSSIBLE INJURY. USE ONLY APPROVED WHEEL ASSEMBLIES. - USE ONLY WHEELS AND LUG NUTS THAT HAVE BEEN DESIGNED FOR CURRENT MODEL YEAR FORD TRUCKS AFTERMARKET WHEELS OR LUG NUTS MAY NOT FIT OR FUNCTION PROPERLY, AND CAN CAUSE PERSONAL INJURY OR DAMAGE THE VEHICLE. - DO NOT MIX DIFFERENT TYPES OF TIRES, SUCH AS RADIAL, BIAS, OR BIAS-BELTED, ON THE SAME VEHICLE EXCEPT IN EMERGENCIES. VEHICLE HANDLING CAN BE SERIOUSLY AFFECTED AND CAN RESULT IN LOSS OF CONTROL. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service Precautions > Customer Safety Information > Page 8000 Tires: Technician Safety Information WARNING: - NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, FOR EXAMPLE, WHEN CHANGING A TIRE. THE WHEEL(S) RESTING ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. - THE TIRE AND WHEEL MUST ALWAYS BE PROPERLY MATCHED. IT IS VERY IMPORTANT TO DETERMINE THE SIZE OF EACH COMPONENT BEFORE ANY ASSEMBLY OPERATIONS COMMENCE. FAILURE TO ADHERE TO THESE INSTRUCTIONS CAN RESULT IN AN EXPLOSIVE SEPARATION AND CAUSE SERIOUS BODILY INJURY OR DEATH. - AFTERMARKET AEROSOL TIRE SEALANTS ARE EXTREMELY FLAMMABLE. ALWAYS QUESTION THE CUSTOMER TO MAKE SURE THESE PRODUCTS HAVE NOT BEEN USED. - AFTERMARKET WHEEL ASSEMBLIES MAY NOT BE COMPATIBLE WITH THE VEHICLE. USE OF INCOMPATIBLE WHEEL ASSEMBLIES CAN RESULT IN EQUIPMENT FAILURE AND POSSIBLE INJURY. USE ONLY APPROVED WHEEL ASSEMBLIES. - USE ONLY WHEELS AND LUG NUTS THAT HAVE BEEN DESIGNED FOR CURRENT MODEL YEAR FORD TRUCKS AFTERMARKET WHEELS OR LUG NUTS MAY NOT FIT OR FUNCTION PROPERLY, AND CAN CAUSE PERSONAL INJURY OR DAMAGE THE VEHICLE. - ALWAYS WEAR SAFETY GOGGLES OR A FACE SHIELD WHEN PERFORMING ANY WORK WITH TIRE AND WHEEL ASSEMBLIES. - DO NOT MIX DIFFERENT TYPES OF TIRES, SUCH AS RADIAL, BIAS, OR BIAS-BELTED, ON THE SAME VEHICLE EXCEPT IN EMERGENCIES. VEHICLE HANDLING CAN BE SERIOUSLY AFFECTED AND CAN RESULT IN LOSS OF CONTROL. - DO NOT BALANCE THE WHEELS AND TIRES WHILE THEY ARE MOUNTED ON THE VEHICLE. POSSIBLE TIRE DISINTEGRATION OR DIFFERENTIAL FAILURE COULD RESULT, CAUSING PERSONAL INJURY AND EXTENSIVE COMPONENT DAMAGE. USE OFF-VEHICLE WHEEL AND TIRE BALANCER ONLY. CAUTION: Reduce the air pressure as much as possible by pushing the valve core plunger in prior to removing the valve core. Avoid working in a position in which the face or body is directly over a tire in which there is pressure. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service Precautions > Customer Safety Information > Page 8001 Tires: Vehicle Damage Warnings WARNING: - NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, FOR EXAMPLE, WHEN CHANGING A TIRE. THE WHEEL(S) RESTING ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. - THE TIRE AND WHEEL MUST ALWAYS BE PROPERLY MATCHED. IT IS VERY IMPORTANT TO DETERMINE THE SIZE OF EACH COMPONENT BEFORE ANY ASSEMBLY OPERATIONS COMMENCE. FAILURE TO ADHERE TO THESE INSTRUCTIONS CAN RESULT IN AN EXPLOSIVE SEPARATION AND CAUSE SERIOUS BODILY INJURY OR DEATH. - AFTERMARKET WHEEL ASSEMBLIES MAY NOT BE COMPATIBLE WITH THE VEHICLE. USE OF INCOMPATIBLE WHEEL ASSEMBLIES CAN RESULT IN EQUIPMENT FAILURE AND POSSIBLE INJURY. USE ONLY APPROVED WHEEL ASSEMBLIES. - USE ONLY WHEELS AND LUG NUTS THAT HAVE BEEN DESIGNED FOR CURRENT MODEL YEAR FORD TRUCKS AFTERMARKET WHEELS OR LUG NUTS MAY NOT FIT OR FUNCTION PROPERLY, AND CAN CAUSE PERSONAL INJURY OR DAMAGE THE VEHICLE. - DO NOT MIX DIFFERENT TYPES OF TIRES, SUCH AS RADIAL, BIAS, OR BIAS-BELTED, ON THE SAME VEHICLE EXCEPT IN EMERGENCIES. VEHICLE HANDLING CAN BE SERIOUSLY AFFECTED AND CAN RESULT IN LOSS OF CONTROL. - DO NOT BALANCE THE WHEELS AND TIRES WHILE THEY ARE MOUNTED ON THE VEHICLE. POSSIBLE TIRE DISINTEGRATION OR DIFFERENTIAL FAILURE COULD RESULT, CAUSING PERSONAL INJURY AND EXTENSIVE COMPONENT DAMAGE. USE OFF-VEHICLE WHEEL AND TIRE BALANCER ONLY. CAUTION: Do not clean aluminum wheels with steel wool. abrasive-type cleaners or strong detergents. Use Custom Bright Metal Cleaner 8A-19522-A or equivalent meeting Ford specifications ESR-M5B194-B. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Tires: Initial Inspection and Diagnostic Overview Verify the customer concern by performing a road test on a smooth road. To maximize tire performances inspect for signs of improper inflation and uneven wear, which may indicate a need for balancing, rotation, or front suspension alignment. Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increases tire wear. Replacement tires must follow the recommended: - tire sizes. - speed rating. - load range. - radial construction type. Use of any other tire size or type can seriously affect: - ride. - handling. - speedometer/odometer calibration. - vehicle ground clearance. - tire clearance between the body and chassis. - wheel bearing life. - brake cooling. Wheels need to be replaced when: - bent. - cracked. - dented. - heavily rusted. - leaking. - they have elongated wheel hub bolt holes. - they have excessive lateral or radial runout. Wheel and tire assemblies are attached by five noncentering lug nuts. It is mandatory to use only the tire sizes recommended on the tire chart attached to the vehicle. Larger or smaller tires can damage the vehicle, affect durability, and require changing the speedometer calibration Make sure wheel size and offsets match those recommended for the tire in use. 1. Inspect for signs of uneven wear that may indicate a need for balancing, rotation front suspension alignments damaged tie rod, or steering components. 2. Check tires for: - cuts. - stone bruises. - abrasions - blisters. - embedded objects. 3. Tread wear indicators are molded into the bottom of the tread grooves. Replace the tire when the indicator bands become visible. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8004 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8005 Tires: Component Tests and General Diagnostics DESCRIPTION Excessive radial and lateral runout of a wheel and tire assembly can cause roughness, vibration, wheel tramp, tire wear, and steering wheel tremor. Before checking runout, and to avoid false readings caused by temporary flat spots in the tires, check runout only after the vehicle has been driven far enough to warm the tires. Measure the extent of the runout with Rotunda Radial Runout Gauge. All measurements are made on the vehicle with the tires inflated to recommended inflation pressures and with the front wheel bearings adjusted to specifications. TIRE RUNOUT Measure radial and lateral tire runout at the positions shown. Runout should not exceed 1.27 mm (0.050 inch). WHEEL RUNOUT Measure radial and lateral wheel runout at the positions shown. Runout should not exceed 1.12 mm (0.044 inch) in either position. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-24-8 > Dec > 05 > Wheels/Tires - Vibration Above 45 MPH Wheels: Customer Interest Wheels/Tires - Vibration Above 45 MPH TSB 05-24-8 12/12/05 VIBRATION/HARSHNESS ABOVE 45 MPH (72 KM/H) AFTER TIRE BALANCE FORD: 1997-2006 E-Series ISSUE Some E-Series vehicles equipped with Single Rear Wheel, 16-inch steel wheels with eight (8) lug bolt holes may experience vehicle vibration at 45 MPH (72 Km/h) or higher after balancing wheel/tire assemblies. ACTION Balancing E-Series steel wheels, both the rear lip of the wheel center opening and the curb side of the lug bolt holes must be used simultaneously to correctly align the assembly on the balancing machine. Balancing machines that include balance, rim runout, and road force variation measurement capabilities like Hunter Models 9100, 9600 or 9700 with the following Service Procedure. SERVICE PROCEDURE NOTE BALANCING E-SERIES STEEL WHEELS, BOTH THE REAR LIP OF THE WHEEL CENTER OPENING AND THE CURB SIDE OF THE LUG BOLT HOLES MUST BE USED SIMULTANEOUSLY TO CORRECTLY ALIGN THE ASSEMBLY ON THE BALANCING MACHINE. Correct positioning of the tire and wheel assemblies on the balancing machine spindle. 1. Install the spacer ring. The spacer ring allows for the wheel offset and prevents contact of the tire with the balancer machine. 2. Install the low-taper cone. Align the cone so that the 110 tapered face engages the wheel center opening. 3. Place the wheel assembly with the curb side of the wheel facing away from the cone. The cone must engage the back of the wheel center opening. 4. Install the flange. Either an adjustable or a fixed flange is suitable. Flange fingers should be adjusted to contact every other lug bolt hole (5 fingers for the 8-bolt wheel) of the bolt circle pattern. 5. Secure the assembly using the appropriate nut on the balancer spindle. NOTE THIS MACHINE SET-UP REPLICATES THE IN-VEHICLE WHEEL POSITION WHERE LUG BOLTS CLAMP THE BACK OF THE WHEEL AGAINST THE AXLE FLANGE. NOTE USE OF A BALANCER MOUNTING CONE ON THE CURB SIDE OF THE WHEEL WILL NOT PERMIT CORRECT WHEEL POSITIONING ON THE BALANCER. THE WHEEL CENTER OPENING IS FORMED FROM THE BACK, AND THE METAL EDGE ON THE CURB SIDE OF THE CENTER OPENING IS NOT DESIGNED TO ACCURATELY POSITION THE WHEEL. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE ALBAL D9 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-24-8 > Dec > 05 > Wheels/Tires - Vibration Above 45 MPH Wheels: All Technical Service Bulletins Wheels/Tires - Vibration Above 45 MPH TSB 05-24-8 12/12/05 VIBRATION/HARSHNESS ABOVE 45 MPH (72 KM/H) AFTER TIRE BALANCE FORD: 1997-2006 E-Series ISSUE Some E-Series vehicles equipped with Single Rear Wheel, 16-inch steel wheels with eight (8) lug bolt holes may experience vehicle vibration at 45 MPH (72 Km/h) or higher after balancing wheel/tire assemblies. ACTION Balancing E-Series steel wheels, both the rear lip of the wheel center opening and the curb side of the lug bolt holes must be used simultaneously to correctly align the assembly on the balancing machine. Balancing machines that include balance, rim runout, and road force variation measurement capabilities like Hunter Models 9100, 9600 or 9700 with the following Service Procedure. SERVICE PROCEDURE NOTE BALANCING E-SERIES STEEL WHEELS, BOTH THE REAR LIP OF THE WHEEL CENTER OPENING AND THE CURB SIDE OF THE LUG BOLT HOLES MUST BE USED SIMULTANEOUSLY TO CORRECTLY ALIGN THE ASSEMBLY ON THE BALANCING MACHINE. Correct positioning of the tire and wheel assemblies on the balancing machine spindle. 1. Install the spacer ring. The spacer ring allows for the wheel offset and prevents contact of the tire with the balancer machine. 2. Install the low-taper cone. Align the cone so that the 110 tapered face engages the wheel center opening. 3. Place the wheel assembly with the curb side of the wheel facing away from the cone. The cone must engage the back of the wheel center opening. 4. Install the flange. Either an adjustable or a fixed flange is suitable. Flange fingers should be adjusted to contact every other lug bolt hole (5 fingers for the 8-bolt wheel) of the bolt circle pattern. 5. Secure the assembly using the appropriate nut on the balancer spindle. NOTE THIS MACHINE SET-UP REPLICATES THE IN-VEHICLE WHEEL POSITION WHERE LUG BOLTS CLAMP THE BACK OF THE WHEEL AGAINST THE AXLE FLANGE. NOTE USE OF A BALANCER MOUNTING CONE ON THE CURB SIDE OF THE WHEEL WILL NOT PERMIT CORRECT WHEEL POSITIONING ON THE BALANCER. THE WHEEL CENTER OPENING IS FORMED FROM THE BACK, AND THE METAL EDGE ON THE CURB SIDE OF THE CENTER OPENING IS NOT DESIGNED TO ACCURATELY POSITION THE WHEEL. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE ALBAL D9 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 8023 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8028 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8029 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8030 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8031 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8032 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8033 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8034 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8035 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8036 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8037 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8038 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8039 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8040 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8041 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8042 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8043 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8044 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8045 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8046 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8047 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8048 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8049 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8050 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8051 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8052 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8053 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8054 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8055 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8056 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8057 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8058 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8059 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8060 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8061 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8062 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8063 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8064 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8065 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8066 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8067 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8068 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8069 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8070 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8071 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8072 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8073 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8074 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8075 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8076 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8077 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8078 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8079 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8080 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8081 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8082 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8083 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8084 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8085 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8086 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8087 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8088 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8089 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8090 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8091 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8092 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8093 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8094 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8095 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8096 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8097 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8098 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8099 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8100 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8101 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8102 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8103 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8104 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8105 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8106 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8107 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8108 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8109 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8110 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8111 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8112 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8113 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8114 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8115 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8116 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8117 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8118 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8119 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8120 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8121 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8122 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 8128 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8133 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8134 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8135 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8136 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8137 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8138 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8139 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8140 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8141 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8142 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8143 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8144 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8145 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8146 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8147 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8148 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8149 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8150 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8151 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8152 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8153 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8154 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8155 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8156 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8157 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8158 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8159 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8160 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8161 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8162 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8163 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8164 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8165 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8166 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8167 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8168 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8169 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8170 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8171 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8172 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8173 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8174 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8175 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8176 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8177 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8178 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8179 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8180 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8181 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8182 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8183 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8184 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8185 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8186 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8187 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8188 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8189 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8190 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8191 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8192 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8193 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8194 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8195 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8196 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8197 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8198 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8199 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8200 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8201 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8202 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8203 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8204 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8205 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8206 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8207 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8208 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8209 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8210 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8211 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8212 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8213 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8214 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8215 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8216 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8217 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8218 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8219 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8220 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8221 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8222 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8223 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8224 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8225 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8226 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8227 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service Precautions > Customer Safety Information Wheels: Customer Safety Information WARNING: - THE TIRE AND WHEEL MUST ALWAYS BE PROPERLY MATCHED. IT IS VERY IMPORTANT TO DETERMINE THE SIZE OF EACH COMPONENT BEFORE ANY ASSEMBLY OPERATIONS COMMENCE. FAILURE TO ADHERE TO THESE INSTRUCTIONS CAN RESULT IN AN EXPLOSIVE SEPARATION AND CAUSE SERIOUS BODILY INJURY OR DEATH. - AFTERMARKET WHEEL ASSEMBLIES MAY NOT BE COMPATIBLE WITH THE VEHICLE. USE OF INCOMPATIBLE WHEEL ASSEMBLIES CAN RESULT IN EQUIPMENT FAILURE AND POSSIBLE INJURY. USE ONLY APPROVED WHEEL ASSEMBLIES. - USE ONLY WHEELS AND LUG NUTS THAT HAVE BEEN DESIGNED FOR CURRENT MODEL YEAR FORD TRUCKS AFTERMARKET WHEELS OR LUG NUTS MAY NOT FIT OR FUNCTION PROPERLY, AND CAN CAUSE PERSONAL INJURY OR DAMAGE THE VEHICLE. - DO NOT MIX DIFFERENT TYPES OF TIRES, SUCH AS RADIAL, BIAS, OR BIAS-BELTED, ON THE SAME VEHICLE EXCEPT IN EMERGENCIES. VEHICLE HANDLING CAN BE SERIOUSLY AFFECTED AND CAN RESULT IN LOSS OF CONTROL. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service Precautions > Customer Safety Information > Page 8230 Wheels: Technician Safety Information WARNING: - NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, FOR EXAMPLE, WHEN CHANGING A TIRE. THE WHEEL(S) RESTING ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. - THE TIRE AND WHEEL MUST ALWAYS BE PROPERLY MATCHED. IT IS VERY IMPORTANT TO DETERMINE THE SIZE OF EACH COMPONENT BEFORE ANY ASSEMBLY OPERATIONS COMMENCE. FAILURE TO ADHERE TO THESE INSTRUCTIONS CAN RESULT IN AN EXPLOSIVE SEPARATION AND CAUSE SERIOUS BODILY INJURY OR DEATH. - AFTERMARKET AEROSOL TIRE SEALANTS ARE EXTREMELY FLAMMABLE. ALWAYS QUESTION THE CUSTOMER TO MAKE SURE THESE PRODUCTS HAVE NOT BEEN USED. - AFTERMARKET WHEEL ASSEMBLIES MAY NOT BE COMPATIBLE WITH THE VEHICLE. USE OF INCOMPATIBLE WHEEL ASSEMBLIES CAN RESULT IN EQUIPMENT FAILURE AND POSSIBLE INJURY. USE ONLY APPROVED WHEEL ASSEMBLIES. - USE ONLY WHEELS AND LUG NUTS THAT HAVE BEEN DESIGNED FOR CURRENT MODEL YEAR FORD TRUCKS AFTERMARKET WHEELS OR LUG NUTS MAY NOT FIT OR FUNCTION PROPERLY, AND CAN CAUSE PERSONAL INJURY OR DAMAGE THE VEHICLE. - ALWAYS WEAR SAFETY GOGGLES OR A FACE SHIELD WHEN PERFORMING ANY WORK WITH TIRE AND WHEEL ASSEMBLIES. - DO NOT MIX DIFFERENT TYPES OF TIRES, SUCH AS RADIAL, BIAS, OR BIAS-BELTED, ON THE SAME VEHICLE EXCEPT IN EMERGENCIES. VEHICLE HANDLING CAN BE SERIOUSLY AFFECTED AND CAN RESULT IN LOSS OF CONTROL. - DO NOT BALANCE THE WHEELS AND TIRES WHILE THEY ARE MOUNTED ON THE VEHICLE. POSSIBLE TIRE DISINTEGRATION OR DIFFERENTIAL FAILURE COULD RESULT, CAUSING PERSONAL INJURY AND EXTENSIVE COMPONENT DAMAGE. USE OFF-VEHICLE WHEEL AND TIRE BALANCER ONLY. CAUTION: Reduce the air pressure as much as possible by pushing the valve core plunger in prior to removing the valve core. Avoid working in a position in which the face or body is directly over a tire in which there is pressure. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service Precautions > Customer Safety Information > Page 8231 Wheels: Vehicle Damage Warnings WARNING: - NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, FOR EXAMPLE, WHEN CHANGING A TIRE. THE WHEEL(S) RESTING ON THE GROUND COULD CAUSE THE VEHICLE TO MOVE. - THE TIRE AND WHEEL MUST ALWAYS BE PROPERLY MATCHED. IT IS VERY IMPORTANT TO DETERMINE THE SIZE OF EACH COMPONENT BEFORE ANY ASSEMBLY OPERATIONS COMMENCE. FAILURE TO ADHERE TO THESE INSTRUCTIONS CAN RESULT IN AN EXPLOSIVE SEPARATION AND CAUSE SERIOUS BODILY INJURY OR DEATH. - AFTERMARKET WHEEL ASSEMBLIES MAY NOT BE COMPATIBLE WITH THE VEHICLE. USE OF INCOMPATIBLE WHEEL ASSEMBLIES CAN RESULT IN EQUIPMENT FAILURE AND POSSIBLE INJURY. USE ONLY APPROVED WHEEL ASSEMBLIES. - USE ONLY WHEELS AND LUG NUTS THAT HAVE BEEN DESIGNED FOR CURRENT MODEL YEAR FORD TRUCKS AFTERMARKET WHEELS OR LUG NUTS MAY NOT FIT OR FUNCTION PROPERLY, AND CAN CAUSE PERSONAL INJURY OR DAMAGE THE VEHICLE. - DO NOT MIX DIFFERENT TYPES OF TIRES, SUCH AS RADIAL, BIAS, OR BIAS-BELTED, ON THE SAME VEHICLE EXCEPT IN EMERGENCIES. VEHICLE HANDLING CAN BE SERIOUSLY AFFECTED AND CAN RESULT IN LOSS OF CONTROL. - DO NOT BALANCE THE WHEELS AND TIRES WHILE THEY ARE MOUNTED ON THE VEHICLE. POSSIBLE TIRE DISINTEGRATION OR DIFFERENTIAL FAILURE COULD RESULT, CAUSING PERSONAL INJURY AND EXTENSIVE COMPONENT DAMAGE. USE OFF-VEHICLE WHEEL AND TIRE BALANCER ONLY. CAUTION: Do not clean aluminum wheels with steel wool. abrasive-type cleaners or strong detergents. Use Custom Bright Metal Cleaner 8A-19522-A or equivalent meeting Ford specifications ESR-M5B194-B. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Wheels: Initial Inspection and Diagnostic Overview Verify the customer concern by performing a road test on a smooth road. To maximize tire performances inspect for signs of improper inflation and uneven wear, which may indicate a need for balancing, rotation, or front suspension alignment. Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increases tire wear. Replacement tires must follow the recommended: - tire sizes. - speed rating. - load range. - radial construction type. Use of any other tire size or type can seriously affect: - ride. - handling. - speedometer/odometer calibration. - vehicle ground clearance. - tire clearance between the body and chassis. - wheel bearing life. - brake cooling. Wheels need to be replaced when: - bent. - cracked. - dented. - heavily rusted. - leaking. - they have elongated wheel hub bolt holes. - they have excessive lateral or radial runout. Wheel and tire assemblies are attached by five noncenter1ng lug nuts. It is mandatory to use only the tire sizes recommended on the tire chart attached to the vehicle. Larger or smaller tires can damage the vehicle, affect durability, and require changing the speedometer calibration Make sure wheel size and offsets match those recommended for the tire in use. 1. Inspect for signs of uneven wear that may indicate a need for balancing, rotation front suspension alignments damaged tie rod, or steering components. 2. Check tires for: - cuts. - stone bruises. - abrasions - blisters. - embedded objects. 3. Tread wear indicators are molded into the bottom of the tread grooves. Replace the tire when the indicator bands become visible. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8234 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8235 Wheels: Component Tests and General Diagnostics DESCRIPTION Excessive radial and lateral runout of a wheel and tire assembly can cause roughness, vibration, wheel tramp, tire wear, and steering wheel tremor. Before checking runout, and to avoid false readings caused by temporary flat spots in the tires, check runout only after the vehicle has been driven far enough to warm the tires. Measure the extent of the runout with Rotunda Radial Runout Gauge. All measurements are made on the vehicle with the tires inflated to recommended inflation pressures and with the front wheel bearings adjusted to specifications. TIRE RUNOUT Measure radial and lateral tire runout at the positions shown. Runout should not exceed 1.27 mm (0.050 inch). WHEEL RUNOUT Measure radial and lateral wheel runout at the positions shown. Runout should not exceed 1.12 mm (0.044 inch) in either position. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Dual Rear Wheels Wheels: Service and Repair Dual Rear Wheels REMOVAL WARNING: - AFTERMARKET WHEEL ASSEMBLIES MAY NOT BE COMPATIBLE WITH THE VEHICLE. USE OF INCOMPATIBLE WHEEL ASSEMBLIES CAN RESULT IN EQUIPMENT FAILURE AND POSSIBLE INJURY. USE ONLY APPROVED WHEEL ASSEMBLIES. - USE ONLY INTEGRAL TWO-PIECE SWIVELING LUG NUTS ON VEHICLES EQUIPPED WITH DUAL REAR WHEELS. DO NOT ATTEMPT TO USE CONE-SHAPED ONE-PIECE LUG NUTS ON THESE VEHICLES. IF USED, CONE-SHAPED ONE-PIECE LUG NUTS CAN COME LOOSE IN VEHICLE OPERATION. DO NOT ATTEMPT TO USE PAST MODEL WHEELS, WHICH HAVE CONE-SHAPED WHEEL HUB BOLT NUT SEATS, ON THIS VEHICLE. DO NOT ATTEMPT TO USE PRESENT DESIGN WHEELS AND LUG NUTS ON PAST MODEL WHEEL HUBS. ATTEMPTED USE OF INTERMIXED WHEELS CAN LEAD TO DAMAGE TO THE WHEEL MOUNTING SYSTEM AND COULD RESULT IN WHEELS COMING LOOSE. 1. Remove the wheel cover if so equipped. 2. With the weight of the vehicle still on the tires, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. NOTE: Do not remove the lug nuts at this time. 3. Raise the vehicle until the wheel and tire assembly clears the floor. 4. Remove the lug nuts. Remove the inner and outer wheel and tire assemblies from the rear hub. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Dual Rear Wheels > Page 8238 INSTALLATION 1. Mount the inner wheel on the rear hub with the wheel dish facing inboard. WARNING: WHEN A WHEEL IS INSTALLED, ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEELS OR THE SURFACES OF THE REAR HUB THAT CONTACT THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUT TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, RESULTING IN LOSS OF CONTROL. 2. Align the wheel with the small indexing hole, located in the wheel between the wheel hub bolt holes, with the alignment pin in the hole in the rear hub. 3. Make sure the wheel is flush with the rear wheel hub mounting surface so there is no gap between the rear hub and the wheel. 4. Install the outer rear wheel flush against the inner wheel with the hub alignment locating pin protruding through the wheel index hole 5. Install the lug nuts and tighten until snug. 6. With the lug nuts loosely installed, turn the wheel until one lug nut is at the top of the wheel hub bolt circle. Tighten the swiveling lug nut until snug. In a crisscross-type pattern, tighten the remaining lug nuts until snug to minimize runout. 7. Lower the vehicle. 8. Tighten the lug nuts to specification. 9. Install the wheel cover, if so equipped. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Dual Rear Wheels > Page 8239 Wheels: Service and Repair Single Wheel REMOVAL 1. Remove the wheel cover, if so equipped. 2. With the weight of the vehicle still on the tires, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. NOTE: Do not remove the lug nuts at this time. 3. Raise the vehicle until the wheel and tire assembly clears the floor. 4. Remove the lug nuts. 5. Remove the wheel and tire assembly. INSTALLATION 1. Position the wheel and tire assembly on the vehicle. WARNING: WHEN A WHEEL IS INSTALLED, ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE FRONT DISC BRAKE HUB AND ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUTS TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, RESULTING IN LOSS OF CONTROL. 2. Install the lug nuts loosely. Make sure the cone ends of the lug nut face inward. 3. Turn the wheel until one lug nut is at the top of the wheel hub bolt circle. Tighten the lug nut until snug. In a crisscross-type pattern tighten the remaining lug nuts until snug to minimize runout. 4. Lower the vehicle. 5. Tighten the lug nuts to specification. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high rotor runout, which will speed up the development of brake roughness, shudder and vibration. 6. Install the wheel cover, if so equipped. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8244 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8245 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8246 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8247 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8248 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8249 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8250 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8251 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8252 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8253 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8254 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8255 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8256 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8257 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8258 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8259 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8260 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8261 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8262 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8263 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8264 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8265 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8266 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8267 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8268 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8269 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8270 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8271 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8272 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8273 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8274 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8275 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8276 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8277 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8278 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8279 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8280 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8281 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8282 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8283 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8284 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8285 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8286 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8287 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8288 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8289 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8290 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8291 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8292 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8293 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8294 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8295 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8296 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8297 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8299 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8300 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8301 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8302 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8303 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8304 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8305 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8306 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8307 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8308 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8309 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8310 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8311 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8312 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8313 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8314 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8315 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8316 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8317 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8318 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8319 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8320 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8321 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8322 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8323 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8324 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8325 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8326 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8327 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8328 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8329 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8330 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8331 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8332 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8333 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8334 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8335 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8336 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8337 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8338 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Front Wheel Bearing: Specifications Front Lubricate the front wheel bearings. Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Front > Page 8341 Wheel Bearing: Specifications Rear Dana Semi-Floating Axle Lubricate the cavity between the lips of the axle shaft oil seal and the rear wheel bearing with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Ford Axles Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 8342 Wheel Bearing: Description and Operation Part 1 Of 2 Part 2 Of 2 SINGLE REAR WHEEL, E-350 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 8343 DUAL REAR WHEEL, E-350 WHEEL HUBS AND BEARINGS The rear hub is supported or floats on the axle spindle on two opposed tapered roller bearings. The rear hub is retained on the spindle by a ratcheting nut that is tabbed to a slot on the spindle. The brake drum is mounted to the rear hub. A seal is installed inboard of the inner rear wheel bearing to keep the rear axle and wheel bearing lubricant from the brake components. The full-floating rear axles on E-350 vehicles have brake drums mounted outboard of the rear hub, permitting brake drum removal for brake inspection without the need to remove the rear hub. The E-Super Duty full-floating axle has rear disc brakes. The rear disc brake rotor is mounted to the rear hub. The rear wheel bearings are packed with a lithium-base grease, Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B, to provide initial lubrication until axle lubricant flows into the rear hubs and rear wheel bearing inner cone and rollers during vehicle operation. Vehicles equipped with Dual Rear Wheel (DRW) rear axles have the wheels attached to the brake drum on the E-350 vehicles or rear hub on E-Super Duty vehicles. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 8344 Wheel Bearing: Testing and Inspection 1. Raise the vehicle until the tire is off the floor. 2. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, adjust the front wheel bearings. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle Wheel Bearing: Service and Repair Dana Semi-Floating Axle Special Tools Special Tools REMOVAL 1. Remove the axle shaft. 2. Remove and discard the axle shaft oil seal from the axle tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 8347 NOTE: If only the seal needs to be replaced, it can be pried out of the tube bore. Use care to avoid damaging the seal bore. NOTE: The axle shaft oil seal can be removed with the rear wheel bearing as a unit. 3. Remove the rear wheel bearing. 1. Install the Front Hub Remover/Replacer, the Hub Remover Adapters and the Rear Axle Bearing Remover. 2. Pull the rear rear wheel bearing from the axle tube. WARNING: WEAR SAFETY GLASSES WHEN REMOVING THE REAR WHEEL BEARING. 4. Clean and inspect the rear wheel bearing bore. - Wipe the bore with emery cloth to ensure a smooth surface. - Clean out the bore with a standard metal-cleaning solvent. Wipe this area clean, making sure it is free of dirt or any other contaminants. NOTE: The rear wheel bearing bore must be free from nicks and burrs. If the bore has burrs or spalled areas and a new rear wheel bearing is installed, early failure can result. INSTALLATION 1. Coat the rear wheel bearing with differential lubricant for easier assembly and to prevent possible scoring of the tube bore. 2. Using the Front Hub Remover/Replacer, Hub Remover Adapters, Step Plate and the Rear Axle Bearing Replacer, install the rear rear wheel bearing. NOTE: During bearing installation, make sure the rear wheel bearing is not cocked in the bore. NOTE: Install the rear wheel bearing, with identification numbers on the rear wheel bearing facing out. 3. Using the Front Hub Remover/Replacer, the Hub Remover Adapters, the Step Plate and the Rear Axle Seal Replacer, install a new axle shaft oil Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 8348 seal. An alternate method of installing the axle shaft oil seal is with the Rear Axle Seal Replacer and Drive Handle. NOTE: Make sure the oil seal is not cocked in the bore during installation. 4. Lubricate the cavity between the lips of the axle shaft oil seal and the rear wheel bearing with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 5. Install the axle shaft. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 8349 Wheel Bearing: Service and Repair Ford 8.8 Inch Ring Gear Special Tools REMOVAL 1. Remove the axle shaft. 2. Use Impact Slide Hammer and Rear Axle Bearing Remover to remove the rear axle bearing and inner wheel bearing oil seal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 8350 NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged. INSTALLATION 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use Axle Tube Bearing Replacer with Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-l-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Use Axle Tube Seal Replacer with Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shaft. 9.75 Inch Ring Gear Special Tools Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 8351 Special Tools REMOVAL 1. Remove the axle shaft. 2. Use the Impact Slide Hammer and the Axle Wheel Bearing Puller to remove the rear wheel bearing and inner wheel bearing oil seal. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged. INSTALLATION 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use the Axle Wheel Bearing Replacer with the Driver Handle to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Dana Semi-Floating Axle > Page 8352 4. Use the Axle Seat Replacer with the Driver Handle to install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub Nut ............................................................................................................................................... ......................................... 88-102 Nm (65-75 ft. lbs.) (Back off 90 degrees, then retighten) ......................................................................................................................................... 20-27 Nm (15-20 ft. lbs.) Maximum Hub Rotating [1] .................................................................................................................. ............................................... 2.3 Nm (20 inch lbs.) [1] Final adjustment is 0 mm (0 inch) end play. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TORQUE SPECIFICATIONS Lug Nut, 8-Lug Wheel 9/16-18: 170-230 Nm (126-170 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the wheel and tire assembly. 3. Remove the front disc brake hub and rotor assembly. 4. Using a suitable press, remove the lug bolt from the front disc brake hub and rotor assembly. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 8362 Wheel Fastener: Service and Repair Rear REMOVAL CAUTION: Never use a hammer to remove the lug bolt. Damage to the axle flange, hub flange, wheel bearing or hub bearing can result. 1. Raise the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. If drum brake, proceed to Step 4. Remove the rear disc brake caliper, rear disc support bracket and rear disc brake rotor if so equipped. Support rear disc brake caliper with safety wire. 4. Remove the rear brake drum. 5. Using C-Frame and Clamp Assembly Tool, press the lug bolt from its seat and discard. INSTALLATION CAUTION: Never use air tools to install lug bolts. The serrations can be stripped from the stud. 1. Insert a new lug bolt in the hole in the axle flange or hub flange, making sure serrations are aligned with those made by the original lug bolt. 2. Seat new lug bolt in axle flange or hub flange. - Place four flatwashers over the outside end of the lug bolt. - Thread a standard lug nut with the flat side against the washers. - Tighten the lug nut until the lug bolt head seats against the back side of the flange. 3. Remove the lug nut and flatwashers. 4. If drum brake, proceed to Step 5. Install the rear disc brake rotor, rear disc support bracket and the rear disc brake caliper, if so equipped. 5. Install the rear brake drum. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 8363 6. Install the wheel and tire assembly. 7. Lower the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Page 8364 Special Tool(s) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications Accumulator HVAC: Specifications Suction Accumulator/Drier Mounting Bolts ...................................................................................................................................... 11-16 N.m (8-11 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8369 Accumulator HVAC: Description and Operation Suction Accumulator/Drier NOTE: Replacement of the suction accumulator/drier is necessary any time a major component of the refrigerant system is replaced. Major components include: - A/C condenser core - A/C compressor - A/C evaporator core - a refrigerant hose/line An A/C evaporator core orifice or O-ring seal is not considered a major component but the A/C evaporator core orifice should be replaced whenever the A/C compressor is replaced for lack of performance. In addition to the preceding condition, the suction accumulator/drier should also be replaced if one of the following conditions exist: - The suction accumulator/drier is perforated. - The refrigerant system has been opened to the atmosphere for a period of time longer than required to make a minor repair. - There is evidence of moisture in the system such as internal corrosion of metal refrigerant lines or the refrigerant oil is thick and dark. The suction accumulator/drier is mounted to the right of the vehicle centerline. The inlet tube of the suction accumulator/drier attaches directly to the A/C evaporator core outlet tube and the outlet tube of the suction accumulator/drier attaches to the A/C manifold and tube. After entering the inlet of the suction accumulator/drier, 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 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8370 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 tube 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. - A fitting located on the top of the suction accumulator/drier is used to attach the A/C cycling switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C cycling switch can be removed without discharging the A/C system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Standard A/C Accumulator HVAC: Service and Repair Standard A/C REMOVAL 1. Using proper procedures, recover the refrigerant. 2. Remove the battery. 3. Remove the battery tray. 1. Remove the screws. 2. Remove the battery tray. 4. Disconnect the evaporator discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 5. Disconnect the compressor suction line. 1. Remove the screw. 2. Disconnect the compressor suction line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Standard A/C > Page 8373 6. Disconnect the A/C cycling switch electrical connector. 7. Remove the suction accumulator/drier. 1. Remove the screws. 2. Remove the suction accumulator/drier. 8. Remove the A/C cycling switch. INSTALLATION 1. Service the replacement suction accumulator/drier with the correct amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Install the A/C cycling switch. - Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Standard A/C > Page 8374 3. Install the suction accumulator/drier. 1. Install the suction accumulator/drier. 2. Install the screws. 4. Connect the A/C cycling switch electrical connector. 5. Connect the evaporator discharge line. - Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 6. Connect the compressor suction line. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the compressor suction line. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Standard A/C > Page 8375 3. Install the screw. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 7. Install the battery tray. 8. Install the battery. 9. Using proper procedures, evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Standard A/C > Page 8376 Accumulator HVAC: Service and Repair Auxiliary A/C and Heater System REMOVAL 1. Using proper procedures, recover the refrigerant. 2. Remove the battery. 3. Remove the battery tray. 1. Remove the screws. 2. Remove the battery tray. 4. Disconnect the evaporator discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 5. Disconnect the auxiliary evaporator to compressor tube spring lock coupling. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Standard A/C > Page 8377 6. Remove the screw. 7. Disconnect the A/C cycling switch connector. 8. Remove the suction accumulator/drier. 1. Remove the screws. 2. Remove the suction accumulator/drier, 9. Remove the A/C cycling switch. INSTALLATION 1. Service the replacement suction accumulator/drier with the correct amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C213-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Standard A/C > Page 8378 2. Install the A/C cycling switch. - Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 3. Install the suction accumulator/drier. 1. Install the suction accumulator/drier. 2. Install the screws. 4. Connect the A/C cycling switch connector. 5. Connect the evaporator discharge line. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the evaporator discharge line. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Standard A/C > Page 8379 6. Connect the auxiliary evaporator to compressor line spring lock coupling. 7. Install the screw. 8. Install the battery tray. 9. Install the battery. 10. Using proper procedures, evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams Blend Door Actuator Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 8384 Air Door Actuator / Motor: Testing and Inspection For component diagnosis, refer to the system level of Heating and Air Conditioning Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator Air Door Actuator / Motor: Service and Repair Air Door Actuator A/C Electronic Door Actuator Motor REMOVAL 1. Disconnect the battery ground cable. 2. Remove the A/C electronic door actuator motor. 1. Disconnect the A/C electronic door actuator motor connector. 2. Remove the four screws. 3. Remove the A/C electronic door actuator motor. INSTALLATION 1. To install, reverse the removal procedure. Auxiliary Vent Door Vacuum Control Motor REMOVAL 1. Remove the air conditioning and heater assembly. 2. Remove the vacuum line. 3. Remove the vacuum control motor. 1. Remove the screw. 2. Unsnap and remove the vacuum control motor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 8387 4. Disconnect the vent door from the vacuum control motor. INSTALLATION 1. Follow the removal procedure in reverse order. Air Inlet Door REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 3. Remove the vacuum line. 4. Remove the two screws. 5. Remove the vacuum control motor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 8388 1. Lift the vacuum control motor arm off of the door crank. 2. Remove the vacuum control motor. INSTALLATION 1. Follow the removal procedure in reverse order. Floor-Defrost REMOVAL 1. Disconnect the battery ground cable. 2. Remove the access panel - Use a screwdriver to pry the access panel out. 3. Remove the vacuum lines. 4. Remove the two screws. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 8389 5. Remove the vacuum control motor. 1. Lift up on the vacuum control motor arm to disengage it from the door crank. 2. Remove the vacuum control motor INSTALLATION 1. Follow the removal procedure in reverse order. Panel REMOVAL 1. Disconnect the battery ground cable. 2. Remove the access panel. - Use a screwdriver to pry the access panel out. 3. Remove the vacuum line. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 8390 4. Remove the two screws. 5. Remove the vacuum control motor. 1. Lift up on the vacuum control motor arm to disengage it from the door crank. 2. Remove the vacuum control motor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 8391 Air Door Actuator / Motor: Service and Repair Blend Door Motor REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 3. Remove the A/C electronic door actuator motor. 1. Disconnect the A/C electronic door actuator motor connector. 2. Remove the four screws. 3. Remove the A/C electronic door actuator motor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C Evaporator Register Air Duct: Service and Repair A/C Evaporator Register REMOVAL 1. Remove the heater outlet floor duct. 2. Remove the steel reinforcement assembly. 3. Remove the screw. 4. Remove the A/C evaporator register duct. 1. Remove the screw. 2. Remove the A/C evaporator register duct. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C Evaporator Register > Page 8396 Air Duct: Service and Repair A/C Vent and Floor REMOVAL 1. Remove the heater outlet floor duct. 2. Remove the steel reinforcement assembly. 3. Remove the screw. 4. Remove the A/C vent and floor duct. 1. Remove the five screws. 2. Remove the A/C vent and floor duct. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C Evaporator Register > Page 8397 Air Duct: Service and Repair Defroster Nozzle REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel. 3. Remove the plenum chamber. 4. Remove the windshield defroster nozzle. 1. Remove the six pushpins. 2. Remove the windshield defroster hose nozzle. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C Evaporator Register > Page 8398 Air Duct: Service and Repair Floor Duct REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel. 3. Move the main wiring. 4. Remove the heater outlet floor duct. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center Air Register: Service and Repair Center REMOVAL 1. Remove the cluster finish panel. 2. Remove the center finish panel. 3. Drill out the heat stakes on the A/C register and remove the A/C register. CAUTION: Use care not to damage the center finish panel. 4. Remove the louver assembly. - Use a screwdriver to pry out the louver assembly. INSTALLATION 1. Install the louver assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center > Page 8403 2. Install the A/C register. 1. Install the A/C register over the service heat stakes. 2. Use a soldering iron to melt the heat stakes. CAUTION: Use care when melting the heat stakes not to melt, warp, or damage the center finish panel. 3. Install the center finish panel. 4. Install the instrument cluster finish panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center > Page 8404 Air Register: Service and Repair Outboard Registers REMOVAL 1. Fabricate a removal tool from a 1/8 inch diameter rod. 2. Rotate the A/C register with the removal tool to align the retaining ears with the clearance openings and remove the A/C register. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center > Page 8405 Air Register: Service and Repair Right and Left REMOVAL 1. Use a small screwdriver to pull out on the two side tabs inside the A/C register. 2. Grasp the center knob and remove the A/C register. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications Blower Motor: Specifications Auxiliary Blower Motor Circuit Protection ....................................................................................................... 50 Amp Fuse in the Power Distribution Box Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Auxiliary Blower Motor System Blower Motor: Description and Operation Auxiliary Blower Motor System The auxiliary air conditioning and heating assembly contains a blower motor. It is controlled by the heater blower motor switch on the front or rear auxiliary A/C control. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Auxiliary Blower Motor System > Page 8411 Blower Motor: Description and Operation Heating and Defrosting Blower Motor The A/C blower motor pulls air from the air inlet and forces it into the plenum assembly where it is mixed and distributed. The A/C blower motor has four speeds and is controlled by the blower motor switch and resistor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Auxiliary Blower Motor Blower Motor: Service and Repair Auxiliary Blower Motor REMOVAL 1. If equipped, remove the third, fourth, and fifth bench seats as required. 2. If equipped, remove the trim panels. - Remove the left center bolster trim panel. - Remove the quarter trim rear upper panel. - Remove the lower rear body side trim panel. 3. Remove the blower motor. 1. Disconnect the electrical connector. 2. Remove the blower motor housing tube. 3. Remove the screws. 4. Remove the blower motor. 4. Remove the blower motor wheel. 1. Remove the retaining clip. 2. Remove the blower motor wheel. NOTE: Note the location of the blower motor wheel on the blower motor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Auxiliary Blower Motor > Page 8414 Blower Motor: Service and Repair Blower Motor REMOVAL 1. Remove the battery. 2. Remove the battery tray. 1. Remove the screws. 2. Remove the battery tray. 3. Move the suction accumulator/drier. 1. Remove the three screws. 2. Move the suction accumulator/drier. NOTE: This step must be performed if the vehicle is equipped with an A/C system. 4. Remove the blower motor. 1. Disconnect the electrical hardshell connector. 2. Remove the blower motor housing tube. 3. Remove four screws. 4. Remove the retaining clip. 5. Remove the blower motor. NOTE: To ease removal, align the flat spot on the blower motor mounting plate with the accumulator. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Auxiliary Blower Motor > Page 8415 5. Remove the blower motor wheel. 1. Remove the retaining clip. 2. Remove the blower motor wheel. NOTE: Note the location of the blower motor wheel on the blower motor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Specifications Blower Motor Relay: Specifications Auxiliary Blower Motor Relay ............................................................................................................... ....................................................... ISO-Type Relay Auxiliary High-Speed Blower Motor Relay .................................................................................................................................................. ISO-Type Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay Blower Motor Relay: Locations Auxiliary Blower Relay Full Body Views The Auxiliary Blower Motor Relay is located at the left rear corner of the vehicle, above wheel well. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay > Page 8421 Blower Motor Relay: Locations Auxiliary High Blower Motor Relay Full Body Views The Auxiliary High Blower Motor Relay is located at the left rear corner of the vehicle, above wheel well. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay > Page 8422 Blower Motor Relay: Locations Blower Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay > Page 8423 Engine Compartment Fuse Box (Part 2 Of 2) The Blower Motor Relay is located at the LH front of the engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay Blower Motor Relay: Diagrams Auxiliary Blower Motor Relay Auxiliary Blower Motor Relay (C403) Auxiliary Blower Motor Relay (C404) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay > Page 8426 Blower Motor Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation Blower Motor Resistor: Description and Operation Blower Motor Resistor Coils Blower Motor Thermal Limiter The heater blower motor switch resistor has the following features: - The assembly is located on the passenger side of the vehicle on the evaporator housing. - Three resistance elements are mounted on the resistor board to provide four A/C blower motor speeds. - Depending on the heater blower motor switch position series resistance is added or bypassed in the A/C blower motor circuit to decrease or increase A/C blower motor speed. - An overheating protective device (thermal limiter) will open the resistor coil circuit when the temperature reaches 121°C (250°F) interrupting the blower motor operation in all speeds except HI. - The thermal limiter cannot be reset and is not serviceable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Blower Motor Resistor: Service and Repair Blower Motor Resistor REMOVAL 1. If equipped, remove the third, fourth, and fifth bench seats as required. 2. If equipped, remove the trim panels. - Remove the left center bolster trim panel. - Remove the quarter trim rear upper panel. - Remove the lower rear body side trim panel. 3. Disconnect the heater blower motor switch resistor connector. 4. Remove the heater blower motor switch resistor. 1. Remove the screws. 2. Remove the heater blower motor switch resistor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor > Page 8432 Blower Motor Resistor: Service and Repair Heater Blower Motor Switch Resistor REMOVAL 1. Remove the battery. 2. Remove the battery tray. 1. Remove the screws. 2. Remove the battery tray. 3. Disconnect the heater blower motor switch resistor connector. 4. Remove the heater blower motor switch resistor. 1. Remove the two screws. 2. Remove the heater blower motor switch resistor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor > Page 8433 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Front Blower Switch Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Front Blower Switch Schematic > Page 8438 C 207 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Front Blower Switch Schematic > Page 8439 Auxiliary Heater Blower Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Front Blower Switch Schematic > Page 8440 Auxiliary Air Conditioner-Heater Blower Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary Blower Motor Switch: Testing and Inspection Auxiliary Auxiliary A/C-Heater Blower Switch - Component Testing Procedure Auxiliary A/C-Heater Blower Switch - Terminal Locations Auxiliary A/C-Heater Blower Switch - Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary > Page 8443 Blower Motor Switch: Testing and Inspection Front Blower Switch Front Blower Switch - Component Testing Procedure Front Blower Switch - Terminal Locations Front Blower Switch - Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary > Page 8444 Blower Motor Switch: Testing and Inspection Rear Auxiliary Rear Auxiliary Blower Switch - Component Testing Procedure Rear Auxiliary Blower Switch - terminal Locations Rear Auxiliary Blower Switch - Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair This model is not equipped with a cabin air filter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications A/C Clutch Air Gap .......................................................................................................................................................... 0.35-0.75 mm (0.014-0.030 Inch) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8452 Compressor Clutch: Description and Operation A/C compressor and Clutch Assembly NOTE: - Internal A/C compressor components are not serviced separately. The FS-10 A/C compressor is serviced only as an assembly. The A/C clutch, A/C clutch pulley, A/C clutch field coil and the shaft seal are serviceable. - Whenever the A/C compressor is replaced, also replace the suction accumulator/drier and the A/C evaporator core orifice. The FS-10 A/C compressor has the following characteristics: - A ten-cylinder swashplate design utilizing the tangential design mount. - Displacement of 170 cc (10 cubic inch). - A one-piece lip-type seal (replaceable from the front of the A/C compressor) is used to seal it at the shaft opening in the assembly. - Five double-acting pistons operate within the cylinder assembly. The pistons are actuated by a swashplate that changes the rotating action of the shaft to a reciprocating force. - Reed-type discharge valves are located between the cylinder assembly and the head at each end of the A/C compressor. - The A/C compressor uses Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. This oil contains special additives required for the A/C compressor. - The A/C compressor oil from vehicles equipped with an FS-10 A/C compressor may have a dark color while maintaining a normal oil viscosity. This is normal for this A/C compressor because carbon from the piston rings will discolor the oil. Compressor Clutch Components The magnetic A/C clutch has the following characteristics: - It drives the compressor shaft. - When battery positive voltage (B+) is applied to the A/C clutch field coil, the clutch plate and hub assembly is drawn toward the A/C clutch pulley. - The magnetic force locks the clutch plate and hub assembly and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8453 - When B+ is removed from the A/C clutch field coil, springs in the clutch plate and hub assembly move the clutch plate away from the A/C clutch pulley. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8454 Compressor Clutch: Adjustments 1. Check the A/C clutch air gap at three equally spaced places between the clutch hub and the A/C clutch pulley. 2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the compressor shaft until clearance is within specification. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8455 Compressor Clutch: Service and Repair Jaw Puller Coil Pressing Tool Compressor Clutch Holding Tool Differential Side Bearing Puller Field Coil Replacer Shaft Protector Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8456 SPECIAL TOOL(S) REMOVAL 1. Remove the A/C compressor. 2. Remove the A/C clutch hub retaining bolt. 1. Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2. Remove the bolt. 3. Remove the A/C clutch and the A/C clutch hub spacer. 1. Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. 2. Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8457 6. Remove the A/C clutch field coil. 1. Note the location of the A/C clutch field coil electrical connector. 2. Install the Shaft Protector for Coil Removal on the nose opening of the A/C compressor. 3. Install the Differential Side Bearing Puller. 4. Remove the A/C clutch field coil. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and pulley bearing mounting surfaces. 2. Install the A/C clutch field coil. 1. Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector properly positioned. 2. Place the Field Coil Replacer on the A/C clutch field coil. Place the Coil Pressing Tool on the Field Coil Replacer. 3. Use the 2-Jaw Puller to install the A/C clutch field coil until bottomed completely against the A/C compressor. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be properly aligned during installation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8458 4. Install the pulley snap ring with the bevel side out. 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 6. Install the A/C clutch. 7. Install the A/C clutch hub retaining bolt. 1. Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2. Tighten the bolt. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8459 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8460 Compressor Clutch: Tools and Equipment Jaw Puller Coil Pressing Tool Compressor Clutch Holding Tool Differential Side Bearing Puller Field Coil Replacer Shaft Protector Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Specifications Compressor Clutch Hub: Specifications GENERAL SPECIFICATIONS Magnetic Clutch Air Gap Between Pulley and Hub ............................................................................................................................ 0.35-0.85 mm (0.014-0.033 Inch) TORQUE SPECIFICATIONS A/C Clutch Hub Retaining Bolt ........................................................................................................................................... 11-14 N.m (98-123 Lb/In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Specifications Compressor Pulley: Specifications Magnetic Clutch Air Gap Between Pulley and Hub .................................................................................................................................. 0.35-0.85 mm (0.014-0.033 Inch) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair Compressor Shaft Seal: Service and Repair Shaft Seal Protector Shaft Seal Remover Shaft Seal Replacer Snap Ring Remover O-Ring Tool SPECIAL TOOL(S) REMOVAL 1. Remove the A/C clutch from the A/C compressor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 8470 2. Remove the shaft seal felt from the nose of the A/C compressor with the O-Ring Remover. 3. Clean the compressor nose area. 4. Insert the tip of the Snap Ring Remover into one of the snap ring eyes. 5. Rotate the Snap Ring Remover to position the tool tip and the snap ring eye closest to the A/C compressor shaft. 6. Pull the Snap Ring Remover up quickly while keeping the tool shaft against the side of the nose opening and remove the snap ring. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 8471 7. Engage the Shaft Seal Remover into the inside diameter of the shaft seal. 8. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal. 9. Pull the seal from the A/C compressor. INSTALLATION 1. Clean the A/C compressor nose area. CAUTION: Do not allow dirt or other foreign materials to enter the A/C compressor. 2. Place the shaft seal on the Shaft Seal Protector. Lubricate the shaft seal and the Shaft Seal Protector with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 8472 3. Position the shaft seal and the Shaft Seal Protector over the A/C compressor shaft. 4. Push the shaft seal onto the A/C compressor shaft with the Shaft Seal Replacer until seated. 5. Install the shaft seal snap ring. 6. Perform the A/C compressor external leak test. 7. Install the shaft seal felt. 8. Install the A/C clutch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 8473 Compressor Shaft Seal: Tools and Equipment Shaft Seal Protector Shaft Seal Remover Shaft Seal Replacer Snap Ring Remover O-Ring Tool Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications Compressor Fitting HVAC: Specifications A/C Manifold and Tube Mounting Bolt .......................................................................................................................................... 18-24 N.m (14-18 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 8477 Compressor Fitting HVAC: Service and Repair REMOVAL 1. Using proper procedures, recover the refrigerant. 2. Disconnect the battery ground cable. 3. Drain the engine cooling system. 4. Remove the drive belt. 5. Remove the fan shroud. 6. Disconnect the A/C pressure cut-off switch electrical connector. 7. Disconnect the compressor suction line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 8. Disconnect the compressor discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 9. Raise and support the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 8478 10. Disconnect the A/C clutch electrical connector. 11. Disconnect the crankshaft position sensor connector. 12. Remove the bolts. 13. Remove the A/C manifold and tube. 1. Slide the A/C compressor forward. 2. Loosen the bolt. 3. Remove the A/C manifold and tube. CAUTION: Support the A/C compressor while removing the A/C manifold and tube to prevent injury or A/C compressor damage. INSTALLATION 1. Service the replacement A/C manifold and tube with the proper amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 8479 2. Install the A/C manifold and tube. 1. Lubricate the new A/C manifold O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings on the A/C compressor. 2. Install the A/C manifold and tube. 3. Apply Pipe Sealant with Teflon(R) D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 to the threads of the A/C manifold retaining bolt and install the bolt. 4. Slide the A/C compressor to the rear. CAUTION: Support the A/C compressor while removing the A/C manifold and tube to prevent injury or A/C compressor damage. 3. Install the bolts. 4. Connect the A/C clutch electrical connector. 5. Connect the crankshaft position sensor connector. 6. Lower the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 8480 7. Connect the compressor discharge line. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the compressor discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 8. Connect the compressor suction line. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the compressor suction line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 9. Connect the A/C pressure cut-off switch electrical connector. 10. Install the fan shroud. 11. Install the drive belt. 12. Fill the engine cooling system. 13. Reconnect the battery ground cable. 14. Using proper procedures, evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications Condenser to Evaporator Tube Fittings ........................................................................................................................................... 15-21 N.m (11-15 Lb/Ft) Condenser Mounting Bracket Screws ............................................................................................................................................... 10-14 N.m (7-10 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8484 Condenser HVAC: Description and Operation A/C Condenser Core NOTE: Whenever an A/C condenser core is replaced, it is also necessary to replace the suction accumulator/drier. The A/C 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 Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8485 Condenser HVAC: Testing and Inspection ON-VEHICLE LEAK TEST 1. Using proper procedures, discharge and recover the refrigerant. See: Service and Repair/Discharging and Recovery 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. 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. 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. 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. 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 replacing the 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 Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8486 Condenser HVAC: Service and Repair REMOVAL NOTE: - Whenever the A/C condenser core is replaced, also replace the suction accumulator/drier. - If an A/C condenser core leak is suspected, the A/C condenser core must be leak-tested before it is removed from the vehicle. 1. Using proper procedures, recover the refrigerant. 2. Remove the air deflector. 1. Remove the five retaining pins. 2. Remove the air deflector. 3. Disconnect the condenser core refrigerant lines. 1. Disconnect the compressor discharge line. 2. Disconnect the condenser to evaporator tube. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 4. Remove the two upper radiator mounting brackets. 1. Remove the screws. 2. Remove the upper radiator mounting brackets. 5. Move the radiator back to gain access. CAUTION: Use care not to damage the cooling fins while handling the radiator. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8487 6. Remove the two A/C condenser mounting brackets. 1. Remove the screw. 2. Remove the A/C condenser mounting bracket. 7. Remove the A/C condenser core. CAUTION: Use care not to damage the cooling fins while handling the A/C condenser core. 8. Remove the two seals. 1. Remove the eight retaining pins. 2. Remove the two seals. INSTALLATION 1. Service the replacement A/C condenser core with the correct amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Install the two seals. 1. Install the two seals. 2. Install the eight retaining pins. 3. Install the A/C condenser core. CAUTION: Use care not to damage the cooling fins while handling the A/C condenser core. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8488 4. Install the two A/C condenser mounting brackets. 1. Install the A/C condenser mounting bracket. 2. Install the screw. 5. Position the radiator. 6. Install the two upper radiator mounting brackets. 1. Install the upper radiator mounting bracket. 2. Install the screws. 7. Install the condenser core refrigerant lines. 1. Lubricate the new O-rings with clean Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the condenser to evaporator tube. 3. Connect the compressor discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8489 9. Install the air deflector. 1. Install the air deflector. 2. Install the five retaining pins. 10. Using proper procedures, evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Air Conditioning and Heating System Control Assembly: Description and Operation Auxiliary Air Conditioning and Heating System The auxiliary A/C-heater system has an optional rear climate control assembly, mounted in the headliner in the rear of the vehicle. This control assembly has the same settings as the heater blower motor switch (located on the A/C control). These switches allow the auxiliary blower motor to be turned off while the main blower motor is operating. By placing the heater blower motor switch in the REAR CONTROL position, the auxiliary blower motor can then be controlled from the rear climate control panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Air Conditioning and Heating System > Page 8494 Control Assembly: Description and Operation Control Components Component Locations The manual climate control system heats or cools the vehicle interior depending on the function selector position and the temperature selected. Function Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Air Conditioning and Heating System > Page 8495 selector position determines heating or cooling and air distribution. The temperature blend control setting determines air temperature. The manual climate control components are used to: - select air inlet source (outside or recirculated). - select blower motor speed. - select discharge air temperature (temperature blend). - select discharge air location (defrost, panel, floor). - select A/C compressor clutch operation. Climate Control Assembly The climate control assembly has three system controls: The A/C heater function selector switch combines a vacuum selector valve with two electrical switches to supply battery positive voltage to the A/C clutch circuit and the blower motor control circuit. - The temperature selection is accomplished with a potentiometer connected to the electric blend door actuator that controls positioning of the temperature blend door. Movement of the control knob from COOL (Blue) to WARM (Red) causes a corresponding movement on the air temperature control door and determines the temperature that the system will maintain. - The blower motor switch controls blower motor speed by adding or bypassing resistors in the heater blower motor switch resistor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Page 8496 Control Assembly: Testing and Inspection Function Selector Switch - Component Testing Procedure Function Selector Switch - Terminal Locations Function Selector Switch - Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly Control Assembly: Service and Repair Air Conditioning and Heater Assembly Heater Hose Disconnect Tool SPECIAL TOOL(S) REMOVAL 1. Using proper procedures, discharge and recover the refrigerant. See: Service and Repair/Discharging and Recovery 2. Drain the engine cooling system. 3. Disconnect and plug the heater water hoses. NOTE: Use the heater hose disconnect tool. 4. Disconnect the refrigerant line spring lock couplings. 5. If equipped, remove the third, fourth and fifth bench seats as required. 6. If equipped, remove the trim panels. - Remove the LH center bolster trim panel. - Remove the quarter trim rear upper panel. - Remove the lower rear body side trim panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly > Page 8499 7. Remove the heater air plenum chamber. 1. Remove the screw. 2. Remove the heater air plenum chamber. 8. Remove the air conditioning and heater assembly. 1. Remove the three screws. NOTE: Vehicles equipped with the interior trim package use only the left two screws. 2. Remove the air conditioning and heater assembly. NOTE: Use care not to spill any remaining coolant or refrigerant oil while removing the air conditioning and heater assembly. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly > Page 8500 Control Assembly: Service and Repair Climate Control Switches REMOVAL 1. Disconnect the battery ground cable. 2. Remove the center trim panel. 3. Remove the control assembly. 1. Remove the screws. 2. Remove the control assembly. 4. Remove the A/C-heater function selector switch knob. 5. Disconnect the vacuum harness connector. 6. Disconnect the A/C-heater function selector switch connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly > Page 8501 7. Remove the A/C-heater function selector switch. 1. Remove the screw. 2. Remove the A/C-heater function selector switch. 8. Remove the temperature control switch knob. 9. Disconnect the temperature control switch connector. 10. Remove the temperature control switch. 1. Remove the screw. 2. Remove the temperature control switch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly > Page 8502 11. Remove the heater blower motor switch knob. 12. Disconnect the heater blower motor switch connector. 13. Remove the heater blower motor switch. 1. Remove the screw. 2. Remove the heater blower motor switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly > Page 8503 Control Assembly: Service and Repair Control Assembly, HVAC REMOVAL 1. Disconnect the battery ground cable. 2. Remove the center trim panel. 3. Remove the control assembly. 1. Remove the screws. 2. Remove the control assembly. 4. Disconnect the vacuum harness and electrical connectors. - Disconnect the vacuum harness connector. - Disconnect the electrical connectors. 5. Remove the control assembly. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly > Page 8504 Control Assembly: Service and Repair Rear Control Assembly REMOVAL 1. Remove the rear climate control panel. - Use a screwdriver to carefully pry the rear climate control panel out of the headliner. 2. Disconnect the electrical hardshell connectors. - Disconnect the heater blower motor switch connector. - Disconnect the lamp connector. 3. Remove the knob. 4. Remove the heater blower motor switch. 1. Remove the screw. 2. Remove the heater blower motor switch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Air Conditioning and Heater Assembly > Page 8505 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Page 8506 Heater Hose Disconnect Tool Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation Coupler HVAC: Description and Operation Spring Lock Coupling The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a circular cage. - 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 two halves of the A/C condenser core couplings, all other couplings have two O-ring seals. - These O-ring seals are green in color and are made of special material. - Use only the green O-ring seals listed in the Ford Master Parts Catalog for the spring lock coupling. - A plastic indicator ring is used on the spring lock couplings of the A/C evaporator core 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 Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Disconnect Tool Set Spring Lock Coupling Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling SPECIAL TOOL(S) DISCONNECT 1. Remove the A/C tube lock coupling clip. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 8512 2. Fit the spring lock coupling disconnect tool to the spring lock coupling. 3. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring. 4. Pull the spring lock coupling fittings apart. 5. Remove the O-ring seals with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring tools. They can cause axial scratches across the O-ring grooves resulting in refrigerant leaks. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 8513 6. Remove the A/C tube lock coupling spring with a small hooked wire. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring grooves resulting in refrigerant leaks. CONNECT 1. Install the A/C tube lock coupling spring. 2. Lubricate the inside of the coupling with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 3. Install the O-ring seals. - Lubricate the O-ring seals with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. CAUTION: Use only new green O-rings. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 8514 4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling spring snaps over the flared end of the female fitting. 5. Install the A/C tube lock coupling clip. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 8515 Coupler HVAC: Service and Repair Spring Lock Coupling-Cleaning Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling SPECIAL TOOL(S) 1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod. 2. Cut an abrasive pad from maroon colored 3M Scotch Brite(R) with the dimensions corresponding to the coupling size. Coupling Size Pad Size 3/8 inch 25 X 50 mm (1 X 2 inch) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 8516 1/2 inch 25 X 50 mm (1 X 2 inch) 5/8 inch 25 X 76 mm (1 X 3 inch) 3/4 inch 25 X 102 mm (1 X 4 inch) 3. Assemble the pad to the tool. 4. Coat the abrasive pad with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 5. Roll the pad on the tool and install it in a variable speed drill motor. 6. Polish for 1 minute at moderate speed (less than 1500 rpm) or until the surface is clean and free of scratches or debris. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. 7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves and scratches are still present, replace the component. 9. Clean the O-ring grooves with a 300 mm (12 inch) length of natural fiber string. - Loop the string around the grooves and pull the string back and forth. 10. Remove any debris from the grooves with a lint free cloth. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 98-5-10 > Mar > 98 > A/C - Unable To Control Temperature Technical Service Bulletin # 98-5-10 Date: 980316 A/C - Unable To Control Temperature Article No. 98-5-10 03/16/98 ^ AIR CONDITIONING - NO TEMPERATURE CONTROL - VEHICLES BUILT THROUGH 2/25/98 ^ HEATER - NO TEMPERATURE CONTROL - VEHICLES BUILT THROUGH 2/25/98 LIGHT TRUCK: 1997-98 ECONOLINE This TSB article is being republished in its entirety to include 1998 model year vehicles and correct the build date of the affected vehicles. ISSUE: Absence of temperature control on some vehicles may be due to the blend door actuator shaft having an interference tit with the blend door, thus causing the blend door to break. ACTION: Replace the heater case assembly with a revised heater case assembly. Refer to the following Service Procedure for details. PART NUMBER PART NAME F7UZ-18478-CA Heater case Assembly OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-4-18 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980510A Replace Heater Case Assembly 1.7 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 18B545 01 OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure 1. Open both driver and passenger side doors. 2. Install memory saver module, then disconnect battery negative cable. 3. Drain cooling system. 4. Using Heater Hose Disconnect Tool (T85T-18539-AH), disconnect and plug heater hoses from the heater core. 5. Remove inside engine cover. 6. Remove passenger side instrument panel finish panel. 7. Remove driver side instrument panel finish panel. 8. Remove passenger side instrument panel finish panel reinforcement. 9. Remove passenger side instrument panel dash brace. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 98-5-10 > Mar > 98 > A/C - Unable To Control Temperature > Page 8525 10. Remove top instrument panel retaining screws. 11. Remove upper left access panel. CAUTION: IF THIS NUT IS REMOVED COMPLETELY, PROBABLE DAMAGE TO COMPONENTS WILL OCCUR FROM INSTRUMENT PANEL FALLING. 12. Loosen instrument panel-to-main bracket retaining nut. 13. Remove instrument panel-to-center finish panel retaining bolts. 14. Slightly raise the instrument panel, then place a 38.1 mm thick by 101.6 mm long by 101.6 mm wide (1-1/2"x4"x4") block of wood on the right front portion of the engine cover opening. This will hold the instrument panel in a raised position. 15. Remove RH kick panel from the engine cover side. 16. Remove heater case cover. 17. Remove heater core. 18. Disconnect the door temperature blend actuator wiring. 19. Remove heater case assembly. 20. Install revised Heater Case Assembly (F7UZ-18478-CA). 21. Transfer temperature blend door actuator to revised heater case assembly. 22. Reverse Steps 1-19 for installation of the revised heater case assembly. Tighten instrument panel bolt to 2-3 N.m (18-27 lb-in). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 98-5-10 > Mar > 98 > A/C - Unable To Control Temperature Technical Service Bulletin # 98-5-10 Date: 980316 A/C - Unable To Control Temperature Article No. 98-5-10 03/16/98 ^ AIR CONDITIONING - NO TEMPERATURE CONTROL - VEHICLES BUILT THROUGH 2/25/98 ^ HEATER - NO TEMPERATURE CONTROL - VEHICLES BUILT THROUGH 2/25/98 LIGHT TRUCK: 1997-98 ECONOLINE This TSB article is being republished in its entirety to include 1998 model year vehicles and correct the build date of the affected vehicles. ISSUE: Absence of temperature control on some vehicles may be due to the blend door actuator shaft having an interference tit with the blend door, thus causing the blend door to break. ACTION: Replace the heater case assembly with a revised heater case assembly. Refer to the following Service Procedure for details. PART NUMBER PART NAME F7UZ-18478-CA Heater case Assembly OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-4-18 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980510A Replace Heater Case Assembly 1.7 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 18B545 01 OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure 1. Open both driver and passenger side doors. 2. Install memory saver module, then disconnect battery negative cable. 3. Drain cooling system. 4. Using Heater Hose Disconnect Tool (T85T-18539-AH), disconnect and plug heater hoses from the heater core. 5. Remove inside engine cover. 6. Remove passenger side instrument panel finish panel. 7. Remove driver side instrument panel finish panel. 8. Remove passenger side instrument panel finish panel reinforcement. 9. Remove passenger side instrument panel dash brace. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 98-5-10 > Mar > 98 > A/C - Unable To Control Temperature > Page 8531 10. Remove top instrument panel retaining screws. 11. Remove upper left access panel. CAUTION: IF THIS NUT IS REMOVED COMPLETELY, PROBABLE DAMAGE TO COMPONENTS WILL OCCUR FROM INSTRUMENT PANEL FALLING. 12. Loosen instrument panel-to-main bracket retaining nut. 13. Remove instrument panel-to-center finish panel retaining bolts. 14. Slightly raise the instrument panel, then place a 38.1 mm thick by 101.6 mm long by 101.6 mm wide (1-1/2"x4"x4") block of wood on the right front portion of the engine cover opening. This will hold the instrument panel in a raised position. 15. Remove RH kick panel from the engine cover side. 16. Remove heater case cover. 17. Remove heater core. 18. Disconnect the door temperature blend actuator wiring. 19. Remove heater case assembly. 20. Install revised Heater Case Assembly (F7UZ-18478-CA). 21. Transfer temperature blend door actuator to revised heater case assembly. 22. Reverse Steps 1-19 for installation of the revised heater case assembly. Tighten instrument panel bolt to 2-3 N.m (18-27 lb-in). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Page 8532 Evaporator Case: Specifications Evaporator Core Housing Support Bracket Upper Screw ............................................................................................................. 2.4-4.0 N.m (22-35 Lb-In) Evaporator Core Housing Support Bracket Lower Screw ....................................................................................................... 10.2-13.8 N.m (91-122 Lb-In) Battery Tray Screws ............................................................................................................................ ............................................ 22-34 N.m (16-25 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Disassembly and Assembly Evaporator Case: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Remove the blower motor. 1. Remove the blower motor housing tube. 2. Remove the four screws. 3. Remove the retaining clip. 4. Remove the blower motor. 2. Remove the heater blower motor switch resistor. 1. Remove the two screws. 2. Remove the heater blower motor switch resistor. 3. Remove the evaporator cover. 1. Remove the six screws. 2. Remove the four screws. 3. Remove the evaporator cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Disassembly and Assembly > Page 8535 4. Remove the A/C evaporator core. 1. Remove the seal. 2. Remove the A/C evaporator core. CAUTION: Use care not to damage or bend the evaporator core cooling fins while handling the A/C evaporator core. ASSEMBLY 1. Follow the disassembly procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Disassembly and Assembly > Page 8536 Evaporator Case: Service and Repair Removal and Installation With Auxiliary A/C REMOVAL 1. Using proper procedures, recover the refrigerant. 2. Remove the battery. 3. Remove the battery tray. 1. Remove the screws. 2. Remove the battery tray. 4. Drain the engine coolant system. 5. Remove the heater core housing. 6. Move the windshield washer reservoir cover out of the way. 1. Remove the screws. 2. Move the windshield washer reservoir cover. 7. Remove the windshield reservoir. 8. Deflect the battery tray support brackets. 9. Remove the suction accumulator/drier. 10. Disconnect the condenser to evaporator tube from the A/C condenser core and A/C evaporator core. NOTE: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 11. Move the A/C refrigeration tube assembly. 1. Remove screw. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Disassembly and Assembly > Page 8537 2. Move the A/C refrigeration tube assembly. 12. Disconnect the blower motor electrical connector. 13. Disconnect the heater blower motor switch resistor electrical connector. 14. Remove the screws and the evaporator core housing support bracket. 15. Remove the evaporator core housing. 1. Remove the seven nuts. 2. Remove the evaporator core housing. NOTE: The use of an assistant may be necessary to install the evaporator core housing. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Disassembly and Assembly > Page 8538 1. Install the evaporator core housing. 1. Install the evaporator core housing. 2. Install the seven nuts. NOTE: The use of an assistant may be necessary to install the evaporator core housing. 2. Install the evaporator core housing support bracket and screws. 3. Connect the heater blower motor switch resistor electrical connector. 4. Connect the blower motor electrical connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Disassembly and Assembly > Page 8539 5. Install the A/C refrigeration tube assembly. 1. Install the A/C refrigeration tube assembly. 2. Install the screw. 6. Connect the condenser to evaporator tube at the A/C condenser core and A/C evaporator core. NOTE: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 7. Install the suction accumulator/drier. 8. Realign the battery tray support brackets. 9. Install the windshield reservoir. 10. Install the windshield washer reservoir cover. 1. Install the windshield washer reservoir cover. 2. Install the screws. 11. Install the heater core housing. 12. Fill the engine coolant system. 13. Install the battery tray. 14. Install the battery. 15. Using proper procedure, evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging With Standard A/C REMOVAL 1. Using proper procedures, recover the refrigerant. 2. Remove the battery. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Disassembly and Assembly > Page 8540 3. Remove the battery tray. 1. Remove the screws. 2. Remove the battery tray. 4. Drain the engine cooling system. 5. Remove the heater core housing. 6. Move the windshield washer reservoir cover. 1. Remove the screws. 2. Move the windshield washer reservoir cover. 7. Remove the windshield fluid reservoir. 8. Deflect the battery tray support brackets. 9. Remove the suction accumulator/drier. 10. Remove the condenser to evaporator tube. 11. Disconnect the blower motor electrical connector. 12. Disconnect the heater blower motor switch resistor electrical connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Disassembly and Assembly > Page 8541 13. Remove the screws and the evaporator core housing support bracket. 14. Remove the evaporator core housing. 1. Remove the seven nuts. 2. Remove the evaporator core housing. NOTE: The use of an assistant may be necessary to remove the evaporator core housing. INSTALLATION 1. Install the evaporator core housing. 1. Install the evaporator core housing. 2. Install the seven nuts. NOTE: The use of an assistant may be necessary for the installation of the evaporator core housing. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Disassembly and Assembly > Page 8542 2. Install the evaporator core housing support bracket and screws. 3. Connect the heater blower motor switch resistor electrical connector. 4. Connect the blower motor electrical connector. 5. Install the condenser to evaporator tube. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 6. Install the suction accumulator/drier. 7. Realign the battery tray support brackets. 8. Install the windshield fluid reservoir. 9. Install the windshield washer reservoir cover. 1. Install the windshield washer reservoir cover. 2. Install the screws. 10. Install the heater core housing. 11. Fill the engine cooling system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Disassembly and Assembly > Page 8543 12. Install the battery tray. 13. Install the battery. 14. Using proper procedures, evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications Evaporator Core: Specifications Condenser to Evaporator Tube Fittings ........................................................................................................................................... 15-21 N.m (11-15 Lb/Ft) Evaporator Discharge Line .............................................................................................................................................................. 35-42 N.m (26-31 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Auxiliary Evaporator Core: Description and Operation Auxiliary The auxiliary A/C system uses a rear-mounted A/C evaporator core which operates in the same manner as the front mounted A/C evaporator core. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Auxiliary > Page 8549 Evaporator Core: Description and Operation With Air Conditioning A/C Evaporator Core NOTE: Whenever an A/C evaporator core is replaced, also replace the suction accumulator/drier. The A/C evaporator core is the plate/fin type with a unique refrigerant flow path. - A mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C evaporator core inlet tube and is routed so it flows through the partitioned first three plate/fin sections. - The next four plate/fin sections are partitioned to force the refrigerant to flow toward the other end of the A/C evaporator core. - Refrigerant then continues over to the remaining five plate/fin sections and then moves out of the A/C evaporator core through the A/C evaporator core outlet tube. - This S-pass flow pattern accelerates the flow of refrigerant and oil through the A/C evaporator core. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 8550 Evaporator Core: Testing and Inspection ON-VEHICLE LEAK TEST 1. Using proper procedures, discharge and recover the refrigerant. See: Service and Repair/Discharging and Recovery 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. 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. 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. 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. 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 replacing the 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 Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary Evaporator Core: Service and Repair Auxiliary REMOVAL NOTE: - Whenever the A/C evaporator core is replaced, also replace the suction accumulator/drier. - If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle. 1. Using proper procedures, recover the refrigerant. 2. Remove the battery. 3. Remove the battery tray. 1. Remove the screws. 2. Remove the battery tray. 4. Move the oil fill pipe out of the way. 1. Remove the screw. 2. Move the oil fill pipe. 5. Move the windshield washer reservoir cover out of the way. 1. Remove the screws. 2. Move the windshield washer reservoir cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary > Page 8553 6. Disconnect the evaporator discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 7. Disconnect the suction accumulator/drier line spring lock coupling. 8. Remove the screw. 9. Disconnect the condenser to evaporator tube. 1. Remove the screw. 2. Disconnect the condenser to evaporator tube. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary > Page 8554 10. Disconnect condenser core refrigerant lines. 1. Disconnect the compressor discharge line. 2. Disconnect the condenser to evaporator tube. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 11. Remove the screws and the evaporator core housing support bracket. 12. Remove the evaporator cover. 1. Remove the six screws. 2. Remove the five screws. 3. Remove the evaporator cover. 13. Remove the A/C evaporator core. 1. Remove the seal. 2. Remove the A/C evaporator core. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary > Page 8555 CAUTION: Use care not to damage the cooling fins while handling the A/C evaporator core. INSTALLATION 1. Service the replacement A/C evaporator core with the correct amount of Motorcraft YN-12c refrigerant oil, or equivalent meeting Ford specification WSH-M1C231-B. 2. Install the A/C evaporator core. 1. Install the A/C evaporator core. 2. Install the seal. CAUTION: Use care not to damage the cooling fins while handling the A/C evaporator core. 3. Install the evaporator cover. 1. Install the evaporator cover. 2. Install the five screws. 3. Install the six screws. 4. Install the evaporator core housing support bracket and screws. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary > Page 8556 5. Connect the condenser core refrigerant lines. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the condenser to evaporator tube. 3. Connect the compressor discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 6. Connect the condenser to evaporator tube. 1. Connect the condenser to evaporator tube. NOTE: Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Install the O-rings. 3. Install the screw. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 7. Connect the auxiliary evaporator to compressor tube spring lock coupling. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary > Page 8557 8. Install the screw. 9. Connect the evaporator discharge line. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the evaporator discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 10. Install the windshield washer reservoir cover. 1. Install the windshield washer reservoir cover. 2. Install the screws. 11. Install the oil fill pipe. 1. Install the oil fill pipe. 2. Install the screw. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary > Page 8558 12. Install the battery tray. 13. Install the battery. 14. Using proper procedures, evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary > Page 8559 Evaporator Core: Service and Repair With Manual A/C REMOVAL NOTE: - Whenever the A/C evaporator core is replaced, also replace the suction accumulator/drier. - If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle. 1. Using proper procedures, recover the refrigerant. 2. Remove the battery. 3. Remove the battery tray. 1. Remove the screws. 2. Remove the battery tray. 4. Move the oil fill pipe out of the way. 1. Remove the screw. 2. Move the oil fill pipe. 5. Move the windshield washer reservoir cover out of the way. 1. Remove the screws. 2. Move the windshield washer reservoir cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary > Page 8560 6. Disconnect the evaporator discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 7. Disconnect the compressor suction line. 1. Remove the screw. 2. Disconnect the compressor suction line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 8. Disconnect the condenser to evaporator tube. 1. Remove the screw. 2. Disconnect the condenser to evaporator tube. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 9. Disconnect condenser core refrigerant lines. 1. Disconnect the compressor discharge line. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary > Page 8561 2. Disconnect the condenser to evaporator tube. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 10. Remove the screws and the evaporator core housing support bracket. 11. Remove the evaporator cover. 1. Remove the six screws. 2. Remove the five screws. 3. Remove the evaporator cover. 12. Remove the A/C evaporator core. 1. Remove the seal. 2. Remove the A/C evaporator core. CAUTION: Use care not to damage the cooling fins while handling the A/C evaporator core. INSTALLATION 1. Service the replacement A/C evaporator core with the correct amount of Motorcraft YN-12c refrigerant oil, or equivalent meeting Ford specification WSH-M1C231-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary > Page 8562 2. Install the A/C evaporator core. 1. Install the A/C evaporator core. 2. Install the seal. CAUTION: Use care not to damage the cooling fins while handling the A/C evaporator core. 3. Install the evaporator cover. 1. Install the evaporator cover. 2. Install the five screws. 3. Install the six screws. 4. Install the evaporator core housing support bracket and screws. 5. Connect the condenser core refrigerant lines. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary > Page 8563 O-rings. 2. Connect the condenser to evaporator tube. 3. Connect the compressor discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 6. Connect the condenser to evaporator tube. 1. Connect the condenser to evaporator tube. NOTE: Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Install the O-rings. 3. Install the screw. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 7. Connect the compressor suction line. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the compressor suction line. 3. Install the screw. 8. Install the windshield washer reservoir cover. 1. Install the windshield washer reservoir cover. 2. Install the screws. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary > Page 8564 9. Install the oil fill pipe. 1. Install the oil fill pipe. 2. Install the screw. 10. Install the battery tray. 11. Install the battery. 12. Using proper procedures, evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations Expansion Block/Orifice Tube: Locations The A/C Expansion/Orifice Tube is located in the condenser to evaporator tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8568 Expansion Block/Orifice Tube: Description and Operation A/C Evaporator Core Orifice NOTE: The A/C evaporator core orifice should be replaced whenever an A/C compressor is replaced. The A/C evaporator core orifice has the following characteristics: - is located in the A/C evaporator core inlet tube. - 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 A/C evaporator core orifice. - O-rings on the A/C evaporator core orifice prevent the high-pressure liquid refrigerant from by-passing the A/C evaporator core orifice. - Adjustment or service cannot be made to the A/C evaporator core orifice assembly. It must be replaced as a unit. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8569 Expansion Block/Orifice Tube: Service and Repair Broken Orifice Tube Extractor Fixed Orifice Tube SPECIAL TOOL(S) REMOVAL 1. Remove the condenser to evaporator tube. - For a fixed orifice tube, perform Steps 2 and 3. - For a broken orifice tube, perform Steps 4 and 5. 2. Engage the Fixed Orifice Tube Remover/Replacer to the A/C evaporator core orifice. 3. Hold the tool T-handle stationary and rotate the tool body to remove the A/C evaporator core orifice. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8570 4. To remove a broken A/C evaporator core orifice, screw the end of the Broken Orifice Tube Extractor into the broken A/C evaporator core orifice. 5. Hold the tool T-handle stationary and rotate the tool body to remove the broken A/C evaporator core orifice. INSTALLATION 1. Lubricate and install the 0-ring seals on the A/C evaporator core orifice. - Use Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Place the A/C evaporator core orifice into the Fixed Orifice Tube Remover/Replacer. 3. Insert the A/C evaporator core orifice into the condenser to evaporator tube until seated. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8571 4. Remove the Fixed Orifice Tube Remover/Replacer. 5. Install the condenser to evaporator tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8572 Expansion Block/Orifice Tube: Tools and Equipment Broken Orifice Tube Extractor Fixed Orifice Tube Remover/Replacer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations Thermostatic Expansion Valve Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations > Page 8576 Expansion Valve: Description and Operation Thermostatic Expansion Valve An A/C evaporator expansion valve regulates the flow of refrigerant into the auxiliary A/C evaporator core. It is also the dividing point in the system between low-pressure and high-pressure sides. The temperature sensing bulb measures the temperature of the refrigerant in the suction line and transmits it to the A/C evaporator expansion valve. This temperature variation regulates the refrigerant flow to the auxiliary A/C evaporator core. - When the bulb senses a high temperature, the A/C evaporator expansion valve opens and provides refrigerant through the auxiliary A/C evaporator core. - When the bulb senses a low temperature, the A/C evaporator expansion valve starts closing to shut off the refrigerant to the auxiliary A/C evaporator core. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations > Page 8577 Expansion Valve: Service and Repair REMOVAL 1. Remove the A/C evaporator core. 2. Remove the thermocouple. 1. Remove the electrical wire wrap tape. 2. Remove the thermocouple. 3. Remove the A/C evaporator expansion valve. 1. Disconnect the refrigerant lines. - Disconnect the A/C liquid jumper line. - Disconnect the inlet line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 2. Remove the A/C evaporator expansion valve. INSTALLATION 1. Install the A/C evaporator expansion valve. 1. Install new green O-rings. - Lubricate with clean Motorcraft Refrigerant Oil YN-12b or equivalent meeting Ford specification WSH-M1C231-B. NOTE: The green O-ring(s) cannot be seen.They are located in the connection(s). 2. Install the A/C evaporator expansion valve. 3. Connect the refrigerant lines. - Connect the A/C liquid jumper line. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations > Page 8578 - Connect the inlet line. 2. Install the thermocouple. - Use electrical wire wrap tape. 3. Install the A/C evaporator core. 4. Using proper procedures, evacuate and charge the system. See: Service and Repair/Evacuation and Charging 5. Check the system for proper operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8587 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8588 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8594 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8595 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Auxiliary Heater Core: Description and Operation Auxiliary The auxiliary A/C system uses a rear-mounted heater core which operates in the same manner as the front mounted heated core. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Auxiliary > Page 8598 Heater Core: Description and Operation Heating and Defrosting Heater Core The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 8599 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. 1. 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. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require replacement. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Perform a system inspection by checking the heater system thoroughly as follows: 2. Check the integrity of the heater water hose clamps. 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. Heater Core-Plugged WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the proper level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot: If it is not hot: the heater core may have an air pocket - the heater core may be plugged - the thermostat is not working properly. Heater Core-Pressure Test Use the Radiator/Heater Core Pressure Tester to perform the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) 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 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three 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 perform the bench test. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 8600 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 inch) 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 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, replace the heater core. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core Heater Core: Service and Repair Back Flushing-Heater Core 1. Once pressure is released, remove the pressure relief cap. WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DAMAGE TO THE COOLING SYSTEM ENGINE OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMOVING THE PRESSURE RELIEF CAP, WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE PRESSURE RELIEF CAP AND TURN IT SLOWLY. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN RELEASED, (STILL WITH A CLOTH) TURN AND REMOVE THE PRESSURE RELIEF CAP. 2. Partially drain the cooling system. 3. Use cooling system Flush-ALL Flush Kit Hardware Package and Drain Kit to backflush the hater core. Use Ford Premium Cooling System Flush F1AZ-19A503-A meeting Ford specification ESR-M14P7A. NOTE: Refer to the cooling system Flush-ALL Operating Instructions for particular vehicle hook-up. 4. Fill the cooling system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 8603 Heater Core: Service and Repair Heating and Defrosting REMOVAL 1. Drain the engine cooling system. 2. Disconnect the battery ground cable. 3. Disconnect the quick disconnect heater hose couplings at the heater core. 4. Plug the heater water hoses with a suitable 5/8-inch or 3/4-inch plug. 5. Remove the engine cover. 6. Remove the instrument panel finish panel. 7. Remove the heater core cover. 1. Remove the seven screws. 2. Remove the heater core cover. - Remove and discard the heater core case seal. 8. Remove the heater core. NOTE: Use care not to spill the coolant remaining in the heater core during removal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 8604 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 8605 Heater Core: Service and Repair With Auxiliary Air Conditioning REMOVAL 1. If equipped, remove the third, fourth, and fifth bench seats as required. 2. If equipped, remove the trim panels. - Remove the left center bolster trim panel. - Remove the quarter trim rear upper panel. - Remove the lower rear body side trim panel. 3. Remove the heater core cover. 1. Remove the screws. 2. Remove the heater core cover. 4. Clamp off the heater water hoses. 5. Disconnect the heater water hoses. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 8606 6. Remove the heater core. 1. Remove the heater core case seal. 2. Remove the heater core. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Page 8607 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Technical Service Bulletins > Customer Interest for Heater Core Case: > 98-5-10 > Mar > 98 > A/C - Unable To Control Temperature Technical Service Bulletin # 98-5-10 Date: 980316 A/C - Unable To Control Temperature Article No. 98-5-10 03/16/98 ^ AIR CONDITIONING - NO TEMPERATURE CONTROL - VEHICLES BUILT THROUGH 2/25/98 ^ HEATER - NO TEMPERATURE CONTROL - VEHICLES BUILT THROUGH 2/25/98 LIGHT TRUCK: 1997-98 ECONOLINE This TSB article is being republished in its entirety to include 1998 model year vehicles and correct the build date of the affected vehicles. ISSUE: Absence of temperature control on some vehicles may be due to the blend door actuator shaft having an interference tit with the blend door, thus causing the blend door to break. ACTION: Replace the heater case assembly with a revised heater case assembly. Refer to the following Service Procedure for details. PART NUMBER PART NAME F7UZ-18478-CA Heater case Assembly OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-4-18 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980510A Replace Heater Case Assembly 1.7 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 18B545 01 OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure 1. Open both driver and passenger side doors. 2. Install memory saver module, then disconnect battery negative cable. 3. Drain cooling system. 4. Using Heater Hose Disconnect Tool (T85T-18539-AH), disconnect and plug heater hoses from the heater core. 5. Remove inside engine cover. 6. Remove passenger side instrument panel finish panel. 7. Remove driver side instrument panel finish panel. 8. Remove passenger side instrument panel finish panel reinforcement. 9. Remove passenger side instrument panel dash brace. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Technical Service Bulletins > Customer Interest for Heater Core Case: > 98-5-10 > Mar > 98 > A/C - Unable To Control Temperature > Page 8616 10. Remove top instrument panel retaining screws. 11. Remove upper left access panel. CAUTION: IF THIS NUT IS REMOVED COMPLETELY, PROBABLE DAMAGE TO COMPONENTS WILL OCCUR FROM INSTRUMENT PANEL FALLING. 12. Loosen instrument panel-to-main bracket retaining nut. 13. Remove instrument panel-to-center finish panel retaining bolts. 14. Slightly raise the instrument panel, then place a 38.1 mm thick by 101.6 mm long by 101.6 mm wide (1-1/2"x4"x4") block of wood on the right front portion of the engine cover opening. This will hold the instrument panel in a raised position. 15. Remove RH kick panel from the engine cover side. 16. Remove heater case cover. 17. Remove heater core. 18. Disconnect the door temperature blend actuator wiring. 19. Remove heater case assembly. 20. Install revised Heater Case Assembly (F7UZ-18478-CA). 21. Transfer temperature blend door actuator to revised heater case assembly. 22. Reverse Steps 1-19 for installation of the revised heater case assembly. Tighten instrument panel bolt to 2-3 N.m (18-27 lb-in). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core Case: > 98-5-10 > Mar > 98 > A/C - Unable To Control Temperature Technical Service Bulletin # 98-5-10 Date: 980316 A/C - Unable To Control Temperature Article No. 98-5-10 03/16/98 ^ AIR CONDITIONING - NO TEMPERATURE CONTROL - VEHICLES BUILT THROUGH 2/25/98 ^ HEATER - NO TEMPERATURE CONTROL - VEHICLES BUILT THROUGH 2/25/98 LIGHT TRUCK: 1997-98 ECONOLINE This TSB article is being republished in its entirety to include 1998 model year vehicles and correct the build date of the affected vehicles. ISSUE: Absence of temperature control on some vehicles may be due to the blend door actuator shaft having an interference tit with the blend door, thus causing the blend door to break. ACTION: Replace the heater case assembly with a revised heater case assembly. Refer to the following Service Procedure for details. PART NUMBER PART NAME F7UZ-18478-CA Heater case Assembly OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-4-18 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980510A Replace Heater Case Assembly 1.7 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 18B545 01 OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure 1. Open both driver and passenger side doors. 2. Install memory saver module, then disconnect battery negative cable. 3. Drain cooling system. 4. Using Heater Hose Disconnect Tool (T85T-18539-AH), disconnect and plug heater hoses from the heater core. 5. Remove inside engine cover. 6. Remove passenger side instrument panel finish panel. 7. Remove driver side instrument panel finish panel. 8. Remove passenger side instrument panel finish panel reinforcement. 9. Remove passenger side instrument panel dash brace. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core Case: > 98-5-10 > Mar > 98 > A/C - Unable To Control Temperature > Page 8622 10. Remove top instrument panel retaining screws. 11. Remove upper left access panel. CAUTION: IF THIS NUT IS REMOVED COMPLETELY, PROBABLE DAMAGE TO COMPONENTS WILL OCCUR FROM INSTRUMENT PANEL FALLING. 12. Loosen instrument panel-to-main bracket retaining nut. 13. Remove instrument panel-to-center finish panel retaining bolts. 14. Slightly raise the instrument panel, then place a 38.1 mm thick by 101.6 mm long by 101.6 mm wide (1-1/2"x4"x4") block of wood on the right front portion of the engine cover opening. This will hold the instrument panel in a raised position. 15. Remove RH kick panel from the engine cover side. 16. Remove heater case cover. 17. Remove heater core. 18. Disconnect the door temperature blend actuator wiring. 19. Remove heater case assembly. 20. Install revised Heater Case Assembly (F7UZ-18478-CA). 21. Transfer temperature blend door actuator to revised heater case assembly. 22. Reverse Steps 1-19 for installation of the revised heater case assembly. Tighten instrument panel bolt to 2-3 N.m (18-27 lb-in). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Heater Core Housing Heater Core Case: Service and Repair Heater Core Housing Removal and Installation REMOVAL 1. Drain the engine cooling system. 2. Disconnect the battery ground cable. 3. Disconnect the quick disconnect heater hose couplings at the heater core. See: Heater Hose/Service and Repair/Heater Hose Couplings 4. Plug the heater water hoses with a suitable 5/8-inch or 3/4-inch plug. 5. Remove the instrument panel.See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 6. Remove the heater core housing. 1. Remove the screw. 2. Remove the nuts. 3. Remove the heater core housing. INSTALLATION 1. Follow the removal procedure in reverse order. Disassembly and Assembly DISASSEMBLY 1. Remove the seal. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Heater Core Housing > Page 8625 2. Remove the heater core cover. 1. Remove the six screws. 2. Remove the heater core cover. - Remove and discard the heater core case seal. 3. Remove the seals. 4. Remove the heater core. 5. Drain the heater core. 6. Remove the A/C electronic door actuator motor. 1. Remove the screws. 2. Remove the A/C electronic door actuator motor. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Heater Core Housing > Page 8626 7. Remove the temperature blend door. 1. Cut the seal. 2. Remove the temperature blend door. ASSEMBLY 1. Follow the disassembly procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Heater Core Housing > Page 8627 Heater Core Case: Service and Repair Plenum Chamber Removal and Installation REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel. 3. Disconnect the vacuum hose connector. 4. Disconnect the vacuum hose. 5. Remove the heater air plenum chamber. 1. Remove the screws. 2. Remove the heater air plenum chamber. INSTALLATION 1. Follow the removal procedure in reverse order. Disassembly and Assembly DISASSEMBLY Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Heater Core Housing > Page 8628 1. Remove the floor/defrost door vacuum control motor. 1. Disconnect vacuum lines. 2. Remove the screws. 3. Lift the vacuum control motor off the door crank. 4. Remove the vacuum control motor. 2. Remove the floor/panel door vacuum control motor. 1. Disconnect the vacuum line. 2. Remove the screws. 3. Lift the vacuum control motor off the door crank. 4. Remove the vacuum control motor. 3. Remove the vacuum lines. ASSEMBLY 1. Follow the disassembly procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8637 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8638 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8644 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8645 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 8646 Heater Hose: Description and Operation A/C Lines And Heater Tubes - Vehicle Underbody, Vans Except RV Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 8647 A/C Lines And Heater Tubes - Vehicle Underbody, Vans And Cutaways The auxiliary A/C system uses a rear-mounted heater core which operates in the same manner as the front mounted heater core. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose Heater Hose: Service and Repair Auxillary Heater Hose A/C Lines And Heater Tubes - Vehicle Underbody, Vans Except RV Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose > Page 8650 A/C Lines And Heater Tubes - Vehicle Underbody, Vans And Cutaways OE provides no specific replacement procedure for these hoses. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose > Page 8651 Heater Hose: Service and Repair Heater Hose Couplings Heater Hose Disconnect Tool SPECIAL TOOL(S) DISCONNECT 1. Depressurize the engine cooling system. WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. Push the Heater Hose Disconnect Tool over the coupling retainer windows to compress the retainer locking tabs. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Tool must be perpendicular to and on the highest point of the coupling. 4. Pull the heater water hose away from the heater core tube. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose > Page 8652 7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer. CONNECT 1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. 2. Install a new coupling retainer, spacer, and lubricated O-rings into the quick disconnect coupling housing. 3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose > Page 8653 Heater Hose: Service and Repair Removal and Installation REMOVAL 1. Drain the cooling system. 2. Disconnect the quick disconnect heater hose couplings at the heater core. 3. Remove the engine cover. 4. Disconnect the supply heater water hose at the engine. 5. Disconnect the return heater water hose at the engine. 6. Disconnect the quick disconnect heater hose couplings from the heater water hoses. NOTE: This step must be performed if the vehicle is equipped with an auxiliary A/C-heater system. 7. Remove the heater water hoses. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxillary Heater Hose > Page 8654 INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Page 8655 Heater Hose Disconnect Tool Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Mechanical Specifications High Pressure Safety Valve HVAC: Mechanical Specifications A/C High Pressure Safety Valve System Protection High-Pressure Relief Valve ............................................................................................................. Common with the Main A/C System Compressor Relief Valve System Protection High-Pressure Relief Valve ............................................................................................................. Common with the Main A/C System Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Mechanical Specifications > Page 8660 High Pressure Safety Valve HVAC: Pressure, Vacuum and Temperature Specifications A/C High Pressure Safety Valve A/C Compressor Pressure Relief Valve Opens at ..................................................................................................................................... 3103 kPa (450 psi) Compressor Relief Valve A/C Compressor Pressure Relief Valve Opens at ..................................................................................................................................... 3103 kPa (450 psi) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > A/C High Pressure Safety Valve High Pressure Safety Valve HVAC: Description and Operation A/C High Pressure Safety Valve An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: - relieve unusually high refrigerant system discharge pressure buildups, (3103 kPa [450 psi] and above). - prevent damage to the A/C compressor and other system components. - avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > A/C High Pressure Safety Valve > Page 8663 High Pressure Safety Valve HVAC: Description and Operation Compressor Relief Valve An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: - relieve unusually high refrigerant system discharge pressure buildups, (3103 kPa [450 psi] and above). - prevent damage to the A/C compressor and other system components. - avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications A/C Liquid Jumper Line ....................................................................................................................... ........................................... 14-20 N.m (10-15 Lb/Ft) Compressor Discharge Line ............................................................................................................................................................ 35-42 N.m (26-31 Lb/Ft) Compressor Suction Line ............................................................................. ................................................................................... 43-51 N.m (32-37 Lb/Ft) Evaporator Discharge Line .............................................................................................................................................................. 35-42 N.m (26-31 Lb/Ft) Inlet Line ...................................................................................................... ................................................................................... 21-27 N.m (15-20 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 8667 Hose/Line HVAC: Description and Operation NOTE: Whenever a refrigerant line is replaced, it is also necessary to replace the suction accumulator/drier. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the following features: - the upstream side contains low pressure refrigerant gas. - the downstream side contains high pressure refrigerant gas. - a serviceable high pressure A/C charge port valve is located on the downstream side. - the downstream side also contains a fitting used to mount the A/C pressure cut-off switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cut-off switch can be removed without discharging the A/C system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line Hose/Line HVAC: Service and Repair A/C Hose/Line Auxiliary A/C-Heater System REMOVAL 1. Using proper procedures, recover the refrigerant. 2. Disconnect the battery ground cable. 3. Partially drain the engine cooling system. 4. Remove the engine air cleaner (ACL) and the air cleaner outlet tube. 5. Disconnect the condenser core refrigerant lines. 1. Disconnect the compressor discharge line. 2. Disconnect the condenser to evaporator tube. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 6. Disconnect the A/C evaporator core fitting. 1. Remove the screw. 2. Disconnect the A/C evaporator core fitting. 7. Remove the four clamps. 1. Remove the screw. 2. Remove the clamp. 8. Raise the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8670 9. Disconnect the underbody tube spring lock coupling. 10. Lower the vehicle. 11. Remove the condenser to evaporator tubes. INSTALLATION 1. Service the replacement condenser to evaporator tube with the proper amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Route the condenser to evaporator tube. 3. Raise the vehicle. 4. Connect the underbody tube spring lock coupling. 5. Lower the vehicle. 6. Connect tile A/C evaporator core fitting. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the A/C evaporator core fitting. 3. Install the screw. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8671 7. Connect the condenser core refrigerant lines. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the condenser to evaporator tube. 3. Connect the compressor discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 8. Install the four clamps. 1. Install the clamp. 2. Install the screw. 9. Install the engine air cleaner and the air cleaner outlet tube. 10. Fill the engine cooling system. 11. Reconnect the battery ground cable. 12. Using proper procedures, evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging Standard A/C REMOVAL 1. Using proper procedures, recover the refrigerant. 2. Disconnect the battery ground cable. 3. Remove the engine Air Cleaner (ACL) and the air cleaner outlet tube. 4. Disconnect the condenser core refrigerant lines. 1. Disconnect the compressor discharge line. 2. Disconnect the condenser to evaporator tube. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8672 5. Disconnect the A/C evaporator core fitting. 1. Remove the screw. 2. Disconnect the A/C evaporator core fitting. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 6. Remove the condenser to evaporator tube. INSTALLATION 1. Service the replacement condenser to evaporator tube with the proper amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Route the condenser to evaporator tube. 3. Connect the A/C evaporator core fitting. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the A/C evaporator core fitting. 3. Install the screw. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 4. Connect the condenser core refrigerant lines. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the condenser to evaporator tube. 3. Connect the compressor discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8673 5. Install the engine air cleaner and the air cleaner outlet tube. 6. Reconnect the battery ground cable. 7. Using proper procedures, evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8674 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Auxiliary A/C Refrigeration Line REMOVAL 1. Remove the condenser to evaporator tube. 2. Disconnect the suction accumulator/drier spring lock coupling. 3. Disconnect the compressor suction line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 4. Remove the four clamps. 1. Remove the screw. 2. Remove the clamp. 5. Raise the vehicle. 6. Disconnect the underbody tube spring lock coupling. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8675 7. Lower the vehicle. 8. Remove the auxiliary A/C refrigeration line. INSTALLATION 1. Service the replacement auxiliary A/C refrigeration line with the proper amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Route the auxiliary A/C refrigeration line. 3. Raise and support the vehicle. 4. Connect the underbody tube spring lock coupling. 5. Lower the vehicle. 6. Connect the compressor suction line. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the compressor suction line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 7. Connect the suction accumulator/drier spring lock coupling. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8676 8. Install the four clamps. 1. Install the clamp. 2. Install the screw. 9. Install the condenser to evaporator tube. Auxiliary A/C-Heater System REMOVAL 1. Using proper procedures, recover the refrigerant. 2. Disconnect the battery ground cable. 3. Partially drain the engine cooling system. 4. Remove the engine air cleaner (ACL) and the air cleaner outlet tube. 5. Disconnect the condenser core refrigerant lines. 1. Disconnect the compressor discharge line. 2. Disconnect the condenser to evaporator tube. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 6. Disconnect the A/C evaporator core fitting. 1. Remove the screw. 2. Disconnect the A/C evaporator core fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8677 7. Remove the four clamps. 1. Remove the screw. 2. Remove the clamp. 8. Raise the vehicle. 9. Disconnect the underbody tube spring lock coupling. 10. Lower the vehicle. 11. Remove the condenser to evaporator tubes. INSTALLATION 1. Service the replacement condenser to evaporator tube with the proper amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Route the condenser to evaporator tube. 3. Raise the vehicle. 4. Connect the underbody tube spring lock coupling. 5. Lower the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8678 6. Connect tile A/C evaporator core fitting. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the A/C evaporator core fitting. 3. Install the screw. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 7. Connect the condenser core refrigerant lines. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the condenser to evaporator tube. 3. Connect the compressor discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 8. Install the four clamps. 1. Install the clamp. 2. Install the screw. 9. Install the engine air cleaner and the air cleaner outlet tube. 10. Fill the engine cooling system. 11. Reconnect the battery ground cable. 12. Using proper procedures, evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging Standard A/C REMOVAL 1. Using proper procedures, recover the refrigerant. 2. Disconnect the battery ground cable. 3. Remove the engine Air Cleaner (ACL) and the air cleaner outlet tube. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8679 4. Disconnect the condenser core refrigerant lines. 1. Disconnect the compressor discharge line. 2. Disconnect the condenser to evaporator tube. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 5. Disconnect the A/C evaporator core fitting. 1. Remove the screw. 2. Disconnect the A/C evaporator core fitting. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 6. Remove the condenser to evaporator tube. INSTALLATION 1. Service the replacement condenser to evaporator tube with the proper amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Route the condenser to evaporator tube. 3. Connect the A/C evaporator core fitting. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the A/C evaporator core fitting. 3. Install the screw. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8680 4. Connect the condenser core refrigerant lines. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the condenser to evaporator tube. 3. Connect the compressor discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 5. Install the engine air cleaner and the air cleaner outlet tube. 6. Reconnect the battery ground cable. 7. Using proper procedures, evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Page 8681 Hose/Line HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications Receiver Dryer: Specifications Suction Accumulator/Drier Mounting Bolts ...................................................................................................................................... 11-16 N.m (8-11 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications > Page 8685 Receiver Dryer: Description and Operation Suction Accumulator/Drier NOTE: Replacement of the suction accumulator/drier is necessary any time a major component of the refrigerant system is replaced. Major components include: - A/C condenser core - A/C compressor - A/C evaporator core - a refrigerant hose/line An A/C evaporator core orifice or O-ring seal is not considered a major component but the A/C evaporator core orifice should be replaced whenever the A/C compressor is replaced for lack of performance. In addition to the preceding condition, the suction accumulator/drier should also be replaced if one of the following conditions exist: - The suction accumulator/drier is perforated. - The refrigerant system has been opened to the atmosphere for a period of time longer than required to make a minor repair. - There is evidence of moisture in the system such as internal corrosion of metal refrigerant lines or the refrigerant oil is thick and dark. The suction accumulator/drier is mounted to the right of the vehicle centerline. The inlet tube of the suction accumulator/drier attaches directly to the A/C evaporator core outlet tube and the outlet tube of the suction accumulator/drier attaches to the A/C manifold and tube. After entering the inlet of the suction accumulator/drier, 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 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications > Page 8686 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 tube 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. - A fitting located on the top of the suction accumulator/drier is used to attach the A/C cycling switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C cycling switch can be removed without discharging the A/C system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Auxiliary A/C and Heater System Receiver Dryer: Service and Repair Auxiliary A/C and Heater System REMOVAL 1. Using proper procedures, recover the refrigerant. 2. Remove the battery. 3. Remove the battery tray. 1. Remove the screws. 2. Remove the battery tray. 4. Disconnect the evaporator discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 5. Disconnect the auxiliary evaporator to compressor tube spring lock coupling. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Auxiliary A/C and Heater System > Page 8689 6. Remove the screw. 7. Disconnect the A/C cycling switch connector. 8. Remove the suction accumulator/drier. 1. Remove the screws. 2. Remove the suction accumulator/drier, 9. Remove the A/C cycling switch. INSTALLATION 1. Service the replacement suction accumulator/drier with the correct amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C213-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Auxiliary A/C and Heater System > Page 8690 2. Install the A/C cycling switch. - Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 3. Install the suction accumulator/drier. 1. Install the suction accumulator/drier. 2. Install the screws. 4. Connect the A/C cycling switch connector. 5. Connect the evaporator discharge line. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the evaporator discharge line. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Auxiliary A/C and Heater System > Page 8691 6. Connect the auxiliary evaporator to compressor line spring lock coupling. 7. Install the screw. 8. Install the battery tray. 9. Install the battery. 10. Using proper procedures, evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Auxiliary A/C and Heater System > Page 8692 Receiver Dryer: Service and Repair Standard A/C REMOVAL 1. Using proper procedures, recover the refrigerant. 2. Remove the battery. 3. Remove the battery tray. 1. Remove the screws. 2. Remove the battery tray. 4. Disconnect the evaporator discharge line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 5. Disconnect the compressor suction line. 1. Remove the screw. 2. Disconnect the compressor suction line. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Auxiliary A/C and Heater System > Page 8693 6. Disconnect the A/C cycling switch electrical connector. 7. Remove the suction accumulator/drier. 1. Remove the screws. 2. Remove the suction accumulator/drier. 8. Remove the A/C cycling switch. INSTALLATION 1. Service the replacement suction accumulator/drier with the correct amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Install the A/C cycling switch. - Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Auxiliary A/C and Heater System > Page 8694 3. Install the suction accumulator/drier. 1. Install the suction accumulator/drier. 2. Install the screws. 4. Connect the A/C cycling switch electrical connector. 5. Connect the evaporator discharge line. - Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 6. Connect the compressor suction line. 1. Lubricate the new O-rings with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and install the O-rings. 2. Connect the compressor suction line. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Auxiliary A/C and Heater System > Page 8695 3. Install the screw. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. 7. Install the battery tray. 8. Install the battery. 9. Using proper procedures, evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8700 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8701 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8702 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8703 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8704 Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8705 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8706 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8707 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity Without Auxiliary .................................................................................................................................. ................................................... 1.47 kg (52 oz) With Auxiliary .......................................................... ................................................................................................................................ 1.81 kg (64 oz) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 8710 Refrigerant: Fluid Type Specifications Refrigerant Type................................................................................................................................... ............................ R-134a YN-19 WSH-M17B19-A Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 8715 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 8716 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 8717 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITY Without Auxiliary .................................................................................................................................. ...................................................... 266 ml (9 oz) With Auxiliary .......................................................... ................................................................................................................................. 384 ml (13 oz) REFRIGERANT OIL ADDING CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. NOTE: Service A/C compressors are shipped without compressor oil. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. ^ If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. ^ If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. ^ If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) (Motorcraft YN-12-C), F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. ^ Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcract YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. 4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when carrying out each of the following repairs: ^ installation of a new A/C evaporator core orifice ^ installation of a new A/C compressor pressure relief valve ^ installation of a new refrigerant line ^ repair of an O-ring seal leak ^ repair of a charge port leak 6. Installation of new components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 8722 Refrigerant Oil: Fluid Type Specifications PAG Oil (R-134a Systems) ...................................................................................................... F7AZ-19589-DA (Motorcraft YN-12-C) WSH-M1C231-B Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications A/C Cycling Switch .............................................................................................................................. ......................................... 1.4-3.8 N.m (13-33 Lb/In) A/C Pressure Cut-Off Switch .......................................................................................................................................................... 7-13 N.m (61-121 Lb/In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 8727 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Cycling Switch Close Maximum ................................................................................................................................... ............................................... 324 kPa (47 psi) Open Minimum ......................................................... .......................................................................................................................... 152 kPa (22 psi) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch A/C Pressure Cut-Off Switch The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1724 kPa (250 psi), the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 8730 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier. - 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 inside the suction accumulator/drier to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). - The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). - When the A/C cycling switch contacts close, the A/C clutch field coil is energized. - When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the A/C cycling switch connector. 2. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. Follow the removal procedure in reverse order. Lubricate the O-ring seal with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 8733 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the A/C pressure cut-off switch electrical connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seal with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Specifications Blower Motor Relay: Specifications Auxiliary Blower Motor Relay ............................................................................................................... ....................................................... ISO-Type Relay Auxiliary High-Speed Blower Motor Relay .................................................................................................................................................. ISO-Type Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay Blower Motor Relay: Locations Auxiliary Blower Relay Full Body Views The Auxiliary Blower Motor Relay is located at the left rear corner of the vehicle, above wheel well. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay > Page 8740 Blower Motor Relay: Locations Auxiliary High Blower Motor Relay Full Body Views The Auxiliary High Blower Motor Relay is located at the left rear corner of the vehicle, above wheel well. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay > Page 8741 Blower Motor Relay: Locations Blower Relay Engine Compartment Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay > Page 8742 Engine Compartment Fuse Box (Part 2 Of 2) The Blower Motor Relay is located at the LH front of the engine compartment, in the engine compartment fuse box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay Blower Motor Relay: Diagrams Auxiliary Blower Motor Relay Auxiliary Blower Motor Relay (C403) Auxiliary Blower Motor Relay (C404) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay > Page 8745 Blower Motor Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Front Blower Switch Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Front Blower Switch Schematic > Page 8751 C 207 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Front Blower Switch Schematic > Page 8752 Auxiliary Heater Blower Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Front Blower Switch Schematic > Page 8753 Auxiliary Air Conditioner-Heater Blower Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary Blower Motor Switch: Testing and Inspection Auxiliary Auxiliary A/C-Heater Blower Switch - Component Testing Procedure Auxiliary A/C-Heater Blower Switch - Terminal Locations Auxiliary A/C-Heater Blower Switch - Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary > Page 8756 Blower Motor Switch: Testing and Inspection Front Blower Switch Front Blower Switch - Component Testing Procedure Front Blower Switch - Terminal Locations Front Blower Switch - Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary > Page 8757 Blower Motor Switch: Testing and Inspection Rear Auxiliary Rear Auxiliary Blower Switch - Component Testing Procedure Rear Auxiliary Blower Switch - terminal Locations Rear Auxiliary Blower Switch - Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications A/C Cycling Switch .............................................................................................................................. ......................................... 1.4-3.8 N.m (13-33 Lb/In) A/C Pressure Cut-Off Switch .......................................................................................................................................................... 7-13 N.m (61-121 Lb/In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 8762 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Cycling Switch Close Maximum ................................................................................................................................... ............................................... 324 kPa (47 psi) Open Minimum ......................................................... .......................................................................................................................... 152 kPa (22 psi) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch A/C Pressure Cut-Off Switch The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1724 kPa (250 psi), the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 8765 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier. - 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 inside the suction accumulator/drier to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). - The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). - When the A/C cycling switch contacts close, the A/C clutch field coil is energized. - When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the A/C cycling switch connector. 2. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. Follow the removal procedure in reverse order. Lubricate the O-ring seal with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 8768 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the A/C pressure cut-off switch electrical connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seal with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation Service Gauge Port Valve The high-pressure service gauge port valve is located on the front A/C manifold and tube. The low pressure service gauge port valve is located on the suction accumulator/drier. 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. - The Schrader-type valve core can be replaced if the seal leaks. - Always install the A/C charging valve cap on the service gauge port valves after repairing the refrigerant system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair Vacuum Harness HVAC: Service and Repair Vacuum Pump Kit SPECIAL TOOL(S) 1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of standard 1/8 inch inner diameter vacuum hose approximately 25 mm (1 inch longer than the damaged area of the mini-tube vacuum hose. 3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. Dip the mini-tube hose ends in commercially available paint thinner containing Methyl Ethyl Ketone (MEK). This solvent will seal the mini-tube in the vacuum hose. WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL. 5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the standard 1/8 inch service vacuum hose. 6. Shake the service joint after assembly to ensure the solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum leak in the repair area. - Use the Vacuum Pump or equivalent. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair > Page 8775 Vacuum Pump Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair Vacuum Reservoir HVAC: Service and Repair REMOVAL 1. Remove the evaporator core housing assembly. Refer to Evaporator Case for this procedure. See: Evaporator Case 2. Remove the vacuum reservoir tank. 1. Remove the screw. 2. Drill out the heat stake. 3. Remove the vacuum reservoir tank. 3. Disconnect the vacuum harness. 3. Remove the EGR vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. NOTE: Use a screw in place of the heat stake to install the vacuum reservoir. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect the battery ground cable(s). WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable(s). REACTIVATION PROCEDURE 1. Disconnect the battery ground cables. WARNING: THE AIR BAG SIMULATORS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Reconnect the passenger air bag module. 7. Reconnect the battery ground cable(s). 8. Prove out the system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8785 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the primary crash sensor connected and mounted to the vehicle? [ ] 2. Is the three-way connector at the base of the steering column connected? [ ] 3. Are the air bag modules and belt and buckle assembly pretensioners or air bag simulators connected? [ ] 4. Is the air bag Electronic Crash Sensor (ECS) module connected? [ ] 5. Is the vehicle battery connected? [ ] Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications Air Bag: Specifications Driver Air Bag Module Screws.............................................................................................................. ........................................10-14 N.m (90-107 Lb/In) Passenger Air Bag Module Nuts.......................................................................................................... ............................................19-26 N.m (14-19 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Air Bag Module Air Bag: Description and Operation Driver Air Bag Module Driver Air Bag Module The driver air bag module: - is replaced as an assembly. - is mounted in the center of the steering wheel. Steering Wheel Trim Cover The steering wheel trim cover: encases the driver air bag module and horn switch. - has tear seams that separate to allow inflation of the air bag. - must not be repainted for any reason. - is a component of the driver air bag module and is not repaired separately. Air Bag The air bag: is constructed of nylon. - is a component of the driver air bag module and is not replaced separately. Inflator The inflator: receives electrical energy when the air bag sensors close. - contains an igniter that converts the electrical signal to thermal energy (heat) causing the ignition of the inflator gas generant. - inflates the air bag with nitrogen gas after the chemical reaction takes place. - is a component of the driver air bag module and is not replaced separately. Mounting Plate and Retainer Ring The mounting plate and retainer ring: attach and seal the air bag to the inflator. - attach the trim cover. - mount the entire driver air bag module to the steering wheel. - are components of the driver air bag module and are not replaced separately. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Air Bag Module > Page 8791 Air Bag: Description and Operation Passenger Air Bag Module Passenger Air Bag Module The passenger air bag module. - is replaced as an assembly. - is mounted in the RH side of the instrument panel. Deployment Door The deployment door: is textured and painted to match the surface of the instrument panel. - is attached to the reaction housing with two nylon web straps and to the instrument panel with spring clips. - disengages from the instrument panel when the air bag inflates and moves out of the way during deployment - is a component of the passenger air bag module and is not replaced separately. Air Bag The air bag: is constructed of nylon. - is a component of the passenger air bag module and is not replaced separately. Inflator The inflator: receives electrical energy when the air bag sensors close. - contains an igniter that converts the electrical signal to thermal energy (heat), causing the ignition of the inflator gas generant. - inflates the air bag with nitrogen after the chemical reaction takes place. - is a component of the passenger air bag module and is not replaced separately. Reaction Housing The reaction housing: provides support for the inflator. - provides a reaction surface for the passenger air bag module. - is used to attach the deployment door with tethers. - contains mounting brackets that attach the passenger air bag module to the instrument panel. - is a component of the passenger air bag module and is not replaced separately. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures Air Bag: Service and Repair Air Bag Disposal Procedures Deployed Air Bag WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. 1. Dispose of the deployed air bag modules in the same manner as any other part to be scrapped. Undeployed Air Bag - Faulty WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER OR DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. NOTE: All inoperative air bag modules have been placed on the Mandatory Return List. All discolored or damaged air bag modules must be treated the same as any inoperative live air bag being returned. 1. Remove the inoperative driver air bag module or passenger air bag module. NOTE: When replacing an air bag module, a prepaid return postcard is provided with the replacement air bag module. The serial number for the new part and the Vehicle Identification Number (VIN) must be recorded and sent to Ford Motor Company. 2. When replacing the driver air bag module, record the necessary information and return the inoperative driver air bag module to Ford Motor Company. 3. When replacing the passenger air bag module, record the necessary information and return the inoperative passenger air bag module to Ford Motor Company. Undeployed Air Bag - Scrapped Vehicle REMOTE DEPLOYMENT WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. - CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER OR DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - REMOTE DEPLOYMENT IS TO BE PERFORMED OUTDOORS WITH ALL PERSONNEL AT LEAST 6.1 METERS (20 FEET) AWAY TO ENSURE PERSONAL SAFETY. DUE TO THE LOUD REPORT WHICH OCCURS WHEN THE AIR BAG IS DEPLOYED, HEARING PROTECTION IS REQUIRED. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures > Page 8794 - DO NOT PLACE THE DRIVER OR PASSENGER AIR BAG MODULE WITH THE TRIM COVER OR DEPLOYMENT DOOR FACING DOWN, AS THE FORCES OF THE DEPLOYING AIR BAG CAN CAUSE IT TO RICOCHET AND CAUSE PERSONAL INJURY. NOTE: The passenger air bag module is shown. The driver air bag module is similar. 1. Remove the air bag module. 2. Cut the two connector wires on the passenger air bag module and strip 25 mm (1 inch) of insulation from the ends of the wires. 3. Obtain two wires at least 6.1 meters (20 feet) long and connect one end of each wire to each of the wires on the passenger air bag module. 4. Place the passenger air bag module on a flat surface with the deployment door facing upward in an open outdoor area. 5. Remain at least 6.1 meters (20 feet) away from the passenger air bag module. 6. Deploy the air bag by touching the other ends of the two wires to the terminals of a 12-volt battery. 7. Allow at least 10 minutes before approaching the deployed air bag to allow for cooling. 8. Dispose of the deployed air bag module in the same manner as any other part to be scrapped. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures > Page 8795 Air Bag: Service and Repair Modification - Procedure For Front Passenger Seat Removal WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: - The safing sensor is internal to the air bag Electronic Crash Sensor (ECS) module and is not replaced separately. - This procedure should be used to modify the air bag Supplemental Restraint System (SRS) on an Econoline van equipped without an optional passenger air bag when the front passenger seat is being removed (cutaway builds are not affected). - The air bag electronic crash sensor (ECS) module Part No. F7UZ- 14A685-A is the module that is released for cutaway vehicles originally built without a front passenger seat and optional passenger air bag. 1. Disconnect the battery ground cable(s). 2. Disconnect the air bag electronic crash sensor (ECS) module electrical connector. 3. Disconnect the safety belt and buckle pretensioner electrical connector. 4. Remove the front passenger seat. 5. Remove the air bag electronic crash sensor (ECS) module. 6. Install a new air bag electronic crash sensor (ECS) module, Part No. F7UZ-14A685-A. 7. Connect the battery ground cable(s). 8. Prove out the system. NOTE: If the air bag indicator flashes a Lamp Fault Code (LFC) during prove out, the LFC will need to be identified and diagnosed. See: Testing and Inspection Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures > Page 8796 Air Bag: Service and Repair Removal and Installation Driver's Side Removal WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. - CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE REPLACED, NOT REPAINTED. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, REPLACE THE SENSOR WHETHER OR NOT THE AIR BAG IS DEPLOYED. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: Repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable(s). 2. Remove the driver air bag module. 1. Remove the two back cover plugs. 2. Remove the two driver air bag module screws. 3. Disconnect the horn electrical connector. 4. Disconnect the air bag sliding contact electrical connector. 5. Remove the driver air bag module. NOTE: Make sure the wheels are in the straight- ahead position. 3. If the driver air bag module is diagnosed as faulty, dispose of the air bag. Refer to Air Bag Disposal. See: Air Bag Disposal Procedures Installation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures > Page 8797 WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. - CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: Repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again Follow the Removal procedure in reverse order. Passenger's Side Removal WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. - CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT WHICH CAN RESULT IN PERSONAL INJURY. - AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE REPLACED, NOT REPAINTED. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, REPLACE THE SENSOR WHETHER OR NOT THE AIR BAG IS DEPLOYED. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: Repair is made by replacement only. If a pan is replaced and the new pan does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable(s). 2. Remove the instrument panel finish panel. 3. Remove the instrument panel finish panel reinforcement Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures > Page 8798 4. Remove the passenger air bag module retaining nuts. 1. Remove the passenger air bag module retaining nuts. 2. Using a 3/8-inch x 4-inch flat head screwdriver, or equivalent, carefully slide the head of the screwdriver under the right bottom edge of the door and lift upward, separating the door from the clip. Separate the rest of the door from the clips by lifting the door with your hands. 5. Remove the passenger air bag module. 1. Disconnect the passenger air bag module electrical connector. 2. Remove the passenger air bag module. 6. Remove the six offset fasteners used for retaining the air bag module door from the instrument panel. 7. If the passenger air bag module is diagnosed as faulty, dispose of the air bag. Refer to Air Bag Disposal. See: Air Bag Disposal Procedures Installation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures > Page 8799 WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. - CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT WHICH CAN RESULT IN PERSONAL INJURY. NOTE: Repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Follow the Removal procedure in reverse order. Place six new offset fasteners onto the air bag module door. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 06-21-18 > Oct > 06 > Restraints - Air Bag Lamp ON/DTC's B1876/B1880/B1920 Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/DTC's B1876/B1880/B1920 TSB 06-21-18 10/30/06 DTC B1876, B1880, B1915 AND/OR B1920 IN THE ECS MODULE DUE TO HIGH CURRENT AFTERMARKET DEVICES FORD: 1997-2006 E-Series This article supersedes TSB 05-2-8 to update the vehicle model years. ISSUE Some vehicles with high-current aftermarket devices (such as motors for wheel chair lifts) operating at 75 amps or higher may cause electrical transients (voltage spikes), leading to damage of the airbag electronic crash sensor (ECS) module. If this occurs, the airbag lamp will turn on indicating a fault in the airbag system and diagnostic trouble codes (DTC) B1876, B1880, B1915 and/or B1920 will be present. ACTION Follow normal diagnostics per Workshop Manual, Section 501-20B. If pinpoint tests lead to replacement of the ECS module, and the vehicle does contain high-current aftermarket equipment, installation of an ECS module circuit protection improvement kit is recommended. This will prevent recurring damage to the new ECS module. SERVICE PROCEDURE Refer to the kit installation instructions. Cost of the protection kit and installation expenses are the responsibility of the modifier or customer. NOTE READ AND FOLLOW ALL WARNINGS LOCATED IN WORKSHOP MANUAL, SECTION 501-20B BEFORE PERFORMING ANY PROCEDURE OR TESTS ON THE RESTRAINTS SYSTEM. Parts Block WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 06-21-18 > Oct > 06 > Restraints - Air Bag Lamp ON/DTC's B1876/B1880/B1920 Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/DTC's B1876/B1880/B1920 TSB 06-21-18 10/30/06 DTC B1876, B1880, B1915 AND/OR B1920 IN THE ECS MODULE DUE TO HIGH CURRENT AFTERMARKET DEVICES FORD: 1997-2006 E-Series This article supersedes TSB 05-2-8 to update the vehicle model years. ISSUE Some vehicles with high-current aftermarket devices (such as motors for wheel chair lifts) operating at 75 amps or higher may cause electrical transients (voltage spikes), leading to damage of the airbag electronic crash sensor (ECS) module. If this occurs, the airbag lamp will turn on indicating a fault in the airbag system and diagnostic trouble codes (DTC) B1876, B1880, B1915 and/or B1920 will be present. ACTION Follow normal diagnostics per Workshop Manual, Section 501-20B. If pinpoint tests lead to replacement of the ECS module, and the vehicle does contain high-current aftermarket equipment, installation of an ECS module circuit protection improvement kit is recommended. This will prevent recurring damage to the new ECS module. SERVICE PROCEDURE Refer to the kit installation instructions. Cost of the protection kit and installation expenses are the responsibility of the modifier or customer. NOTE READ AND FOLLOW ALL WARNINGS LOCATED IN WORKSHOP MANUAL, SECTION 501-20B BEFORE PERFORMING ANY PROCEDURE OR TESTS ON THE RESTRAINTS SYSTEM. Parts Block WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8813 Air Bag Control Module: Specifications Electronic Crash Sensor Module Bolts................................................................................................. .............................................11-13 N.m (8-10 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8814 Air Bag Control Module: Locations Instrument Panel Views The Air Bag Electronic Crash Sensor is located below the RH side (Passenger Side) of the instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8815 Air Bag Electronic Crash Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8816 Air Bag Control Module: Description and Operation The air bag Electronic Crash Sensor (ECS) module performs the following functions: - deploys the air bags and seat belt pretensioners in the event of a deployable crash. - monitors the air bag Supplemental Restraint System (SRS) for faults. - illuminates the air bag indicator if a fault is detected. - flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. - communicates through the Data Link Connector (DLC) the current and historical Diagnostic Trouble Codes (DTCs). - activates a chime or buzzer if the air bag indicator is not available. The ECS, together with the primary crash sensor, determines when to deploy the air bags and belt and buckle assembly pretensioners. The ECS monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the ECS will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off then turned on), the air bag indicator will flash the two-digit lamp fault code (LFC). The air bag indicator will flash the LFC twice, then it will remain illuminated for the rest of the key cycle. The ECS will also communicate the current and historical DTCs through the data link connector (DLC), using the New Generation Star (NGS) Tester. If the air bag indicator does not function, and the system detects a fault condition, the ECS will activate an audible chime or buzzer. The chime is a series of five sets of five tone bursts. The buzzer is a five-seconds-on, five-seconds-off buzzing noise. If the chime or buzzer is heard, the SRS or the air bag indicator requires service. Lamp fault codes are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. The ECS includes an internal backup power supply. This feature provides sufficient backup power to deploy the air bag in the event the battery or battery cables are damaged in a collision before the safing and primary crash sensors close. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. There are three types of 1998 E-Series ECS modules: a two-ignitor system for a school bus, a three-ignitor system for a cargo van and a four-ignitor system for a passenger van. These ECS modules have unique part numbers and are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8817 Air Bag Control Module: Service and Repair Removal WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: The safing sensor is internal to the air bag Electronic Crash Sensor (ECS) module and is not replaced separately. 1. Disconnect the battery ground cable(s). 2. Remove the RH cowl side trim panel. 3. Disconnect the air bag electronic crash sensor (ECS) module electrical connector. 1. Disconnect the ECS electrical connector locking clip. 2. Disconnect the ECS electrical connector. 4. Remove the air bag electronic crash sensor (ECS) module. 1. Remove the ECS module retaining bolts. 2. Remove the ECS module. Installation Follow the Removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation Clockspring Assembly / Spiral Cable: Description and Operation The air bag sliding contact: - is mounted on the steering column tube, behind the steering wheel. - continuously transfers electrical signals from the driver air bag module to the air bag sensors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 8821 Clockspring Assembly / Spiral Cable: Service and Repair Removal WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. - CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE REPLACED, NOT REPAINTED. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: A repair is made by replacement only. if a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Remove the driver air bag module. 2. Remove the steering wheel. NOTE: Make sure the wheels are in the straight-ahead position. 3. If so equipped twist the tilt wheel handle and shank and remove 4. Remove the lower steering column shroud. 1. Remove the three screws. 2. Remove the steering column shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 8822 5. Remove the ignition switch lock cylinder. 1. Position the lock cylinder to RUN. 2. Using a suitable tool, push upward on the cylinder release tab through the hole in the lower shroud while pulling the cylinder outward 6. Carefully pry to release the clips and remove the steering column opening cover. 7. Remove the upper steering column shroud. 8. Prevent accidental rotation of the air bag sliding contact. 1. Check to see if the service lock is missing. 2. If the service lock is missing, apply two strips of masking tape across the air bag sliding contact. NOTE: The air bag sliding contact has a service lock that prevents accidental rotation when the steering wheel is removed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 8823 9. Remove the key-in-ignition warning indicator switch. 10. Disconnect the air bag sliding contact electrical connector and separate the air bag electrical connector from the bracket. 11. Pry the retaining clips loose. 12. Separate the wire from the two retaining clips holding the wire to the column. 13. Remove the air bag sliding contact. - Feed the wiring harness through the instrument panel. Installation WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. - CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: Repair is made by replacement only. If a pan is replaced and the new pan does not correct the condition, install the original part and perform the diagnostic procedure again. 1. If the lock is missing, realign the air bag sliding contact 1. Rotate the air bag sliding contact rotor counterclockwise until it stops. 2. Rotate two revolutions 3. Install per instructions. NOTE: The air bag sliding contact has a service lock that prevents rotation of the air bag sliding contact when the steering wheel is removed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 8824 2. Properly orientate the air bag sliding contact. 1. The air bag electrical pigtail must point to the three o'clock position. 2. The dot on the steering shaft must be at the nine o'clock position. 3. Press at the six, twelve and three o'clock positions to seat the air bag sliding contact. 4. Rotate the wiring and secure into two wire clips. 5. Connect the two electrical connectors. Snap into the bracket 6. Install the key-in-ignition warning indicator switch. 7. If a new clockspring is used, remove the yellow anti-rotation tab 8. Install the upper steering column shroud. 9. Install the ignition switch lock cylinder. 1. Turn the ignition switch lock cylinder to the RUN position 2. Insert the ignition switch lock cylinder into the steering column housing. 3. Make sure the ignition switch lock cylinder is fully seated and aligned in the inter-locking washer before turning the key to the OFF position This will permit the retaining pin of the ignition switch lock cylinder to extend into the hole in the steering column. 10. Rotate the ignition switch lock cylinder, using the key, to make sure of correct mechanical operation in all positions. 11. Install the lower steering column shroud. 12. Install the steering column opening cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 8825 13. If so equipped, install the tilt wheel handle and shank. 14. Install the steering wheel. NOTE: Make sure the front wheels are in the straight-ahead position. 15. Install the driver air bag module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Primary Crash Sensor Screws............................................................................................................. ...............................................11-13 N.m (8-10 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications > Page 8829 Impact Sensor: Locations Engine Compartment Views The Center Air Bag Sensor is located in front center of the engine compartment, behind grille. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications > Page 8830 Impact Sensor: Description and Operation WARNING: THE ECS AND PRIMARY CRASH SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION WHERE THE RADIATOR GRILLE, FRAME RAILS OR RIGHT COWL PANEL HAS BEEN DAMAGED, INSPECT THE MOUNTINGS AND BRACKETS FOR DEFORMATION. IF DAMAGED, THE PRIMARY CRASH SENSOR OR ECS MUST BE REPLACED WHETHER OR NOT THE AIR BAG MODULES HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE PRIMARY CRASH SENSOR MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. NOTE: - The safing sensor is internal to the ECS and is not serviced separately. - If the primary crash sensor is undamaged after a collision, it will automatically reset and can be reused. The SRS contains three sensors located in the following spots: - the ECS, mounted behind the RH cowl side trim panel. - the primary crash sensor mounted on the center radiator support. - the safing sensor, which is internal to the ECS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications > Page 8831 Impact Sensor: Service and Repair Removal WARNING: - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, REPLACE THE SENSOR WHETHER OR NOT THE AIR BAG IS DEPLOYED. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: Repair is made by replacement only. If a part is replaced and the new part does not correct the condition install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable(s). 2. Remove the radiator grille. 3. Disconnect the primary crash sensor electrical connector. 4. Remove the primary crash sensor. 1. Remove the screws. 2. Remove the primary crash sensor. Installation WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, REPLACE THE SENSOR WHETHER OR NOT THE AIR BAG IS DEPLOYED. NOTE: Repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications > Page 8832 1. Follow the Removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module Side Air Bag: Service and Repair Driver Side Air Bag Module Removal WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. - CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE REPLACED, NOT REPAINTED. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, REPLACE THE SENSOR WHETHER OR NOT THE AIR BAG IS DEPLOYED. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: Repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable(s). 2. Remove the driver air bag module. 1. Remove the two back cover plugs. 2. Remove the two driver air bag module screws. 3. Disconnect the horn electrical connector. 4. Disconnect the air bag sliding contact electrical connector. 5. Remove the driver air bag module. NOTE: Make sure the wheels are in the straight- ahead position. 3. If the driver air bag module is diagnosed as faulty, dispose of the air bag. Refer to Air Bag Disposal. See: Air Bag/Service and Repair/Air Bag Disposal Procedures Installation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 8837 WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. - CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: Repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again Follow the Removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 8838 Side Air Bag: Service and Repair Passenger Side Air Bag Removal WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. - CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT WHICH CAN RESULT IN PERSONAL INJURY. - AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE REPLACED, NOT REPAINTED. - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, REPLACE THE SENSOR WHETHER OR NOT THE AIR BAG IS DEPLOYED. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: Repair is made by replacement only. If a pan is replaced and the new pan does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable(s). 2. Remove the instrument panel finish panel. 3. Remove the instrument panel finish panel reinforcement 4. Remove the passenger air bag module retaining nuts. 1. Remove the passenger air bag module retaining nuts. 2. Using a 3/8-inch x 4-inch flat head screwdriver, or equivalent, carefully slide the head of the screwdriver under the right bottom edge of the door and lift upward, separating the door from the clip. Separate the rest of the door from the clips by lifting the door with your hands. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 8839 5. Remove the passenger air bag module. 1. Disconnect the passenger air bag module electrical connector. 2. Remove the passenger air bag module. 6. Remove the six offset fasteners used for retaining the air bag module door from the instrument panel. 7. If the passenger air bag module is diagnosed as faulty, dispose of the air bag. Refer to Air Bag Disposal. See: Air Bag/Service and Repair/Air Bag Disposal Procedures Installation WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. - CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT WHICH CAN RESULT IN PERSONAL INJURY. NOTE: Repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Follow the Removal procedure in reverse order. Place six new offset fasteners onto the air bag module door. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Standby Power Supply, Air Bag > Component Information > Service Precautions Standby Power Supply: Service Precautions WARNING: THE BACKUP POWER SUPPLY ENERGY MUST BE DEPLETED BEFORE ANY AIR BAG COMPONENT SERVICE IS PERFORMED. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE NEGATIVE BATTERY CABLE AND WAIT ONE MINUTE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Standby Power Supply, Air Bag > Component Information > Service Precautions > Page 8843 Standby Power Supply: Description and Operation The Electronic Crash Sensor (ECS) includes an internal backup power supply. This feature provides sufficient backup power to deploy the air bag in the event the battery or battery cables are damaged in a collision before the safing and primary crash sensors close. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations Air Bag Supplemental Restraint System (SRS) Components Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 06-21-18 > Oct > 06 > Restraints - Air Bag Lamp ON/DTC's B1876/B1880/B1920 Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/DTC's B1876/B1880/B1920 TSB 06-21-18 10/30/06 DTC B1876, B1880, B1915 AND/OR B1920 IN THE ECS MODULE DUE TO HIGH CURRENT AFTERMARKET DEVICES FORD: 1997-2006 E-Series This article supersedes TSB 05-2-8 to update the vehicle model years. ISSUE Some vehicles with high-current aftermarket devices (such as motors for wheel chair lifts) operating at 75 amps or higher may cause electrical transients (voltage spikes), leading to damage of the airbag electronic crash sensor (ECS) module. If this occurs, the airbag lamp will turn on indicating a fault in the airbag system and diagnostic trouble codes (DTC) B1876, B1880, B1915 and/or B1920 will be present. ACTION Follow normal diagnostics per Workshop Manual, Section 501-20B. If pinpoint tests lead to replacement of the ECS module, and the vehicle does contain high-current aftermarket equipment, installation of an ECS module circuit protection improvement kit is recommended. This will prevent recurring damage to the new ECS module. SERVICE PROCEDURE Refer to the kit installation instructions. Cost of the protection kit and installation expenses are the responsibility of the modifier or customer. NOTE READ AND FOLLOW ALL WARNINGS LOCATED IN WORKSHOP MANUAL, SECTION 501-20B BEFORE PERFORMING ANY PROCEDURE OR TESTS ON THE RESTRAINTS SYSTEM. Parts Block WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 06-21-18 > Oct > 06 > Restraints - Air Bag Lamp ON/DTC's B1876/B1880/B1920 Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/DTC's B1876/B1880/B1920 TSB 06-21-18 10/30/06 DTC B1876, B1880, B1915 AND/OR B1920 IN THE ECS MODULE DUE TO HIGH CURRENT AFTERMARKET DEVICES FORD: 1997-2006 E-Series This article supersedes TSB 05-2-8 to update the vehicle model years. ISSUE Some vehicles with high-current aftermarket devices (such as motors for wheel chair lifts) operating at 75 amps or higher may cause electrical transients (voltage spikes), leading to damage of the airbag electronic crash sensor (ECS) module. If this occurs, the airbag lamp will turn on indicating a fault in the airbag system and diagnostic trouble codes (DTC) B1876, B1880, B1915 and/or B1920 will be present. ACTION Follow normal diagnostics per Workshop Manual, Section 501-20B. If pinpoint tests lead to replacement of the ECS module, and the vehicle does contain high-current aftermarket equipment, installation of an ECS module circuit protection improvement kit is recommended. This will prevent recurring damage to the new ECS module. SERVICE PROCEDURE Refer to the kit installation instructions. Cost of the protection kit and installation expenses are the responsibility of the modifier or customer. NOTE READ AND FOLLOW ALL WARNINGS LOCATED IN WORKSHOP MANUAL, SECTION 501-20B BEFORE PERFORMING ANY PROCEDURE OR TESTS ON THE RESTRAINTS SYSTEM. Parts Block WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8861 Air Bag Control Module: Specifications Electronic Crash Sensor Module Bolts................................................................................................. .............................................11-13 N.m (8-10 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8862 Air Bag Control Module: Locations Instrument Panel Views The Air Bag Electronic Crash Sensor is located below the RH side (Passenger Side) of the instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8863 Air Bag Electronic Crash Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8864 Air Bag Control Module: Description and Operation The air bag Electronic Crash Sensor (ECS) module performs the following functions: - deploys the air bags and seat belt pretensioners in the event of a deployable crash. - monitors the air bag Supplemental Restraint System (SRS) for faults. - illuminates the air bag indicator if a fault is detected. - flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. - communicates through the Data Link Connector (DLC) the current and historical Diagnostic Trouble Codes (DTCs). - activates a chime or buzzer if the air bag indicator is not available. The ECS, together with the primary crash sensor, determines when to deploy the air bags and belt and buckle assembly pretensioners. The ECS monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the ECS will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off then turned on), the air bag indicator will flash the two-digit lamp fault code (LFC). The air bag indicator will flash the LFC twice, then it will remain illuminated for the rest of the key cycle. The ECS will also communicate the current and historical DTCs through the data link connector (DLC), using the New Generation Star (NGS) Tester. If the air bag indicator does not function, and the system detects a fault condition, the ECS will activate an audible chime or buzzer. The chime is a series of five sets of five tone bursts. The buzzer is a five-seconds-on, five-seconds-off buzzing noise. If the chime or buzzer is heard, the SRS or the air bag indicator requires service. Lamp fault codes are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. The ECS includes an internal backup power supply. This feature provides sufficient backup power to deploy the air bag in the event the battery or battery cables are damaged in a collision before the safing and primary crash sensors close. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. There are three types of 1998 E-Series ECS modules: a two-ignitor system for a school bus, a three-ignitor system for a cargo van and a four-ignitor system for a passenger van. These ECS modules have unique part numbers and are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8865 Air Bag Control Module: Service and Repair Removal WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: The safing sensor is internal to the air bag Electronic Crash Sensor (ECS) module and is not replaced separately. 1. Disconnect the battery ground cable(s). 2. Remove the RH cowl side trim panel. 3. Disconnect the air bag electronic crash sensor (ECS) module electrical connector. 1. Disconnect the ECS electrical connector locking clip. 2. Disconnect the ECS electrical connector. 4. Remove the air bag electronic crash sensor (ECS) module. 1. Remove the ECS module retaining bolts. 2. Remove the ECS module. Installation Follow the Removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect the battery ground cable(s). WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable(s). REACTIVATION PROCEDURE 1. Disconnect the battery ground cables. WARNING: THE AIR BAG SIMULATORS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Reconnect the passenger air bag module. 7. Reconnect the battery ground cable(s). 8. Prove out the system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8871 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the primary crash sensor connected and mounted to the vehicle? [ ] 2. Is the three-way connector at the base of the steering column connected? [ ] 3. Are the air bag modules and belt and buckle assembly pretensioners or air bag simulators connected? [ ] 4. Is the air bag Electronic Crash Sensor (ECS) module connected? [ ] 5. Is the vehicle battery connected? [ ] Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Child Safety Seat Tether Attachment Child Seat Tether Attachment: Description and Operation Child Safety Seat Tether Attachment Some manufacturers make safety seats with a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point behind the seat. Ford recommends the placement of tethered safety seats in a rear seating position, with the tether strap attached to the tether anchoring point. The right front seating position can be used if it is the only seating position available. The tether anchor attachment point for the right front seating position is located on the rear edge of the seat. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Child Safety Seat Tether Attachment > Page 8877 Child Seat Tether Attachment: Description and Operation Tether Anchor Hardware Tether anchor points are provided in the vehicle for child safety seats requiring a tether anchor. Tether anchor hardware kits are available at no cost through Ford or Lincoln-Mercury dealership parts departments. These kits have instructions and hardware specific to the applicable vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications Seat Belt: Specifications TIGHTENING SPECIFICATIONS Belt and Buckle Assembly, Pretensioner Bolt..............................................................................................................................34-46 N.m (25-34 Lb/Ft) Detachable Safety Belt Anchor Buckle End Bolt.........................................................................................................................34-46 N.m (25-34 Lb/Ft) Rear Buckle End Bolt................................................................................................................. .................................................34-46 N.m (25-34 Lb/Ft) Rear Safety Belt and Buckle Bolt................. ...............................................................................................................................34-46 N.m (25-34 Lb/Ft) Safety Belt Retractor Bolts......................................................................................................... ..................................................34-46 N.m (25-34 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and Operation > Automatic Locking Retractor (ALR) Mode Seat Belt: Description and Operation Automatic Locking Retractor (ALR) Mode NOTE: The Automatic Locking Retractor (ALR) mode is not available on the driver safety belt. In the automatic locking retractor (ALR) mode, the shoulder belt is automatically pre-locked. However, the belt will still retract to remove any slack in the shoulder belt. This mode is used any time a child safety seat is installed in an outboard seating position, or when a tight lap/shoulder belt fit is desired. The ALR mode is automatically engaged when the webbing is fully extracted from the retractor. As the webbing is retracted back onto the spool, an audible clicking sound is made, indicating that the retractor is in the ALR mode. The ALR mode is automatically disengaged when the webbing is retracted back onto the spool. ALR mode is disengaged when the audible clicking sound ceases and the webbing is free to move in or out of the retractor, indicating that the belt has returned to the vehicle sensitive (emergency) locking mode of operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and Operation > Automatic Locking Retractor (ALR) Mode > Page 8883 Seat Belt: Description and Operation Belt and Buckle Assembly - Pretensioner The belt and buckle assembly pretensioner is a pyrotechnic device that removes excess webbing from the safety belt system. The belt and buckle assembly pretensioner uses the same crash sensor system as the air bag Supplemental Restraint System (SRS). When the belt and buckle assembly pretensioner deploys, the buckle moves downward, pulling excess webbing from the lap and shoulder safety belts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation Seat Belt: Service and Repair Removal and Installation Front Buckle End Safety Belt Bolt Bit Special Tool(s) Required Removal WARNING: - THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG-EQUIPPED VEHICLE AND WHEN HANDLING A BELT AND BUCKLE ASSEMBLY PRETENSIONER. - THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. NEVER PROBE THE CONNECTORS ON THE BELT AND BUCKLE ASSEMBLY PRETENSIONERS. DOING SO COULD RESULT IN BELT AND BUCKLE ASSEMBLY PRETENSIONER OR AIR BAG DEPLOYMENT AND COULD RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Disconnect the battery ground cable. On vehicles equipped with dual batteries: Disconnect the secondary positive cable from the primary battery terminal. Wrap secondary positive cable with non-conductive material to insulate it. NOTE: Make sure the tool does not contact any ground surface. The secondary battery positive cable remains energized after disconnection. - Disconnect primary battery ground cable - Disconnect primary battery positive cable. NOTE: Failure to accurately follow the battery disconnect procedures will result in vehicle or component damage. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. On the driver side, remove the front seat back latch lower cover. 3. On the passenger side, remove the front seat back pivot side outer cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8886 4. Remove the belt and buckle assembly pretensioner. 1. Disconnect the belt and buckle assembly pretensioner harness connector. 2. Using the Safety Belt Bolt Bit, remove the belt and buckle assembly pretensioner retaining bolt. 3. Remove the belt and buckle assembly pretensioner. Installation WARNING: - THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG-EQUIPPED VEHICLE AND WHEN HANDLING A BELT AND BUCKLE ASSEMBLY PRETENSIONER. - THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. NEVER PROBE THE CONNECTORS ON THE BELT AND BUCKLE ASSEMBLY PRETENSIONERS. DOING SO COULD RESULT IN BELT AND BUCKLE ASSEMBLY PRETENSIONER OR AIR BAG DEPLOYMENT AND COULD RESULT IN PERSONAL INJURY. 1. Follow the removal procedure in reverse order. Align both anti-rotation tabs on the belt and buckle assembly pretensioner into the seat track prior to tightening the bolt. 2. Reconnect negative battery cable. On vehicles equipped with dual batteries: - Reconnect primary battery terminal connections. - Reconnect positive battery cable. - Reconnect the negative battery cable. - Unwrap the secondary battery positive cable and reconnect it to the primary battery positive terminal. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module ( PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. - Make sure to tighten bolts to specification shown in image(s). Front Shoulder Seat Belt Height Adjuster Safety Belt Bolt Bit Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8887 Special Tool(s) Required Removal 1. Remove the front seat shoulder strap guide cover. 2. Remove the shoulder strap guide. 1. Remove the shoulder strap guide nut. 2. Remove the shoulder strap guide. 3. On the driver side, remove the body side trim finish panel and the front upper body side trim panel. 4. On the passenger side, remove the center body pillar upper trim panel. 5. Remove the height adjuster cover. 6. Remove the shoulder safety belt height adjuster. 1. Use the Safety Belt Bolt Bit to remove the bolts. 2. Remove the shoulder safety belt height adjuster. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8888 Installation 1. Follow the removal procedure in reverse order. - Check the restraint system for proper operation. NOTE: Make sure the safety belt webbing is not twisted prior to installation. - Make sure to tighten bolts to specification shown in image(s). 3-Passenger Bench Seat Safety Belt Bolt Bit Special Tool(s) Required Removal 1. Use the Safety Belt Bolt Bit to remove the LH rear safety belt and buckle bolt. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8889 2. Remove the LH rear safety belt and buckle. 3. Use the Safety Belt Bolt Bit to remove the RH rear safety belt and buckle bolt. 4. Remove the RH rear safety belt and buckle. Installation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8890 1. Follow the removal procedure in reverse order. - Check the restraint system for proper operation. NOTE: Make sure the safety belt webbing is not twisted prior to installation. - Make sure to tighten bolts to specification shown in image(s). 4-Passenger Bench Seat Safety Belt Bolt Bit Special Tool(s) Required Removal 1. Use the Safety Belt Bolt Bit to remove the LH rear safety belt and buckle bolt. 2. Remove the LH rear safety belt and buckle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8891 3. Use the Safety Belt Bolt Bit to remove the safety belt and tongue bolt. 4. Remove the safety belt and tongue. 5. Use the Safety Belt Bolt Bit to remove the RH rear safety belt and buckle bolt. 6. Remove the RH rear safety belt and buckle. Installation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8892 1. Follow the removal procedure in reverse order. - Check the restraint system for proper operation. NOTE: Make sure the safety belt webbing is not twisted prior to installation. - Make sure to tighten bolts to specification shown in image(s). Rear Captains Chair Safety Belt Bolt Bit Special Tool(s) Required Removal Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8893 1. Remove the buckle end. 1. Use the Safety Belt Bolt Bit to remove the buckle end bolt. 2. Remove the buckle end. Installation 1. Follow the removal procedure in reverse order. NOTE: Make sure to tighten bolts to specification shown in image(s). Front Seat Safety Belt Safety Belt Bolt Bit Special Tool(s) Required Removal NOTE: Safety belt buckles, pyrotechnic safety belt buckle pretensioners, height adjusters, center adjust tongues and belts and retractors can be replaced separately. However, if a safety belt assembly was in use during a collision, the belt and retractor must be replaced as well as the center adjust tongue and belt and buckle assembly or the center adjust tongue and the cable and buckle assembly. When replacing safety belts and buckles, pyrotechnic safety belt buckle pretensioners, height adjusters, safety cables and buckles, center adjust tongues and belts and retractors, use only the replacement parts specified in the Ford Master Parts Catalogs for the make and model of the vehicle being serviced. Safety belt assemblies must not be interchanged between vehicle models. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8894 1. Remove the front seat shoulder strap guide cover. 2. Remove the shoulder strap guide. 1. Remove the shoulder strap guide nut. 2. Remove the shoulder strap guide. 3. On the driver side, remove the front door scuff plate, the body side trim finish panel, the front upper body side trim panel, and the front lower body side trim panel. 4. Remove the front safety belt retractor. 1. Use the Safety Belt Bolt Bit to remove the bolt. 2. Remove the front safety belt retractor. 5. On the driver side, remove the front safety belt anchor. 1. Use the Safety Belt Bolt Bit to remove the bolt. 2. Remove the front safety belt anchor. 6. On the passenger side, remove the front door scuff plate, the center body pillar upper trim panel and the center body pillar lower trim panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8895 7. Remove the front safety belt retractor and the front safety belt anchor. 1. Use the Safety Belt Bolt Bit to remove the retractor bolt. 2. Remove the front safety belt retractor. 3. Use the Safety Belt Bolt Bit to remove the anchor bolt. 4. Remove the front safety belt anchor. Installation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8896 1. Follow the removal procedure in reverse order. - Check the restraint system for proper operation. NOTE: - Make sure the safety belt webbing is not twisted prior to installation. - Make sure to tighten bolts to specification shown in image(s). Rear Seats Safety Belt Bolt Bit Special Tool(s) Required Removal 1. On a rear safety belt retractor and tongue with a flip-up shoulder strap guide cover, remove the shoulder strap guide as follows. 1. Lift the shoulder strap guide cover. 2. Use the Safety Belt Bolt Bit to remove the bolt. 3. Remove the shoulder strap guide. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8897 2. On a rear safety belt retractor and tongue without a flip-up shoulder strap guide cover, remove the shoulder strap guide as follows. 1. Position the shoulder strap guide cover aside. 2. Use the Safety Belt Bolt Bit to remove the bolt. 3. Remove the shoulder strap guide. 3. On the LH second row rear safety belt retractor and tongue, remove the quarter trim finish panel, the body side rear center lower trim panel and the quarter trim panel. 4. On the LH third, fourth and fifth row rear safety belt retractor and tongues, remove the quarter trim rear upper panel and the quarter trim rear lower panel. 5. On the RH rear safety belt retractor and tongue, remove the quarter trim upper panel, the quarter trim lower panel, the quarter trim rear upper panel and the body side trim cover rear. 6. Remove the safety belt retractor. 1. Remove the safety belt guide. 2. Use the Safety Belt Bolt Bit to remove the bolt. 3. Remove the safety belt retractor. 7. On a rear safety belt retractor and tongue with a detachable safety belt anchor, disengage the detachable safety belt anchor. 1. Insert a key or small screwdriver into the slot in the detachable anchor and lift upward. 2. Disengage the detachable anchor tongue end from the detachable anchor. 8. On a rear safety belt retractor and tongue without a detachable safety belt anchor, remove the safety belt anchor. 1. Use the Safety Belt Bolt Bit to remove the bolt. 2. Remove the safety belt anchor. Installation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8898 1. Follow the removal procedure in reverse order. - Check the restraint system for proper operation. NOTE: Make sure the safety belt webbing is not twisted prior to installation. - Make sure to tighten bolts to specification shown in image(s). Safety Belt Buckle - Detachable Anchor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8899 Safety Belt Bolt Bit Special Tool(s) Required Removal 1. On quad bucket captain chairs, remove the detachable safety belt anchor buckle end. 1. Use the Safety Belt Bolt Bit to remove the detachable safety belt anchor buckle end bolt. 2. Remove the detachable safety belt anchor buckle end. 2. On 3-passenger bench seats, remove the detachable safety belt anchor buckle end. 1. Use the Safety Belt Bolt Bit to remove the detachable safety belt anchor buckle end bolt. 2. Remove the detachable safety belt anchor buckle end. Installation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8900 1. Follow the removal procedure in reverse order. NOTE: Make sure to tighten bolts to specification shown in image(s). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8901 Seat Belt: Service and Repair Service Procedures Post Collision Inspection WARNING: ALL SAFETY BELT ASSEMBLIES, INCLUDING RETRACTORS, SAFETY BELT HEIGHT ADJUSTERS, BUCKLES, BELT AND BUCKLE ASSEMBLY PRETENSIONERS, FRONT SAFETY BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), IF SO EQUIPPED, CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Safety belt assemblies should be periodically inspected to make sure they have not become damaged and are in proper operating condition, particularly if subjected to severe stress. 2. 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 or distorted, the sheet metal must be worked back to its original shape and structural integrity. 3. Install the new safety belt(s). Refer to the appropriate procedure. Perform the Functional Test Safety Belt procedure. See: Testing and Inspection/Component Tests and General Diagnostics Safety Belt Tongue Rotated on Belt 1. Grasp the belt tongue and pull down on the closest belt webbing to form a loop through the upper (narrower and longer) slot in the tongue. 2. Working within the upper slot, rotate and fold the belt webbing over itself as required to remove the twist. 3. Pull the excess belt webbing back through the upper slot in the tongue. 4. Repeat Steps 1-3 to complete the removal of the twist at the lower (wider and larger) slot in the tongue. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8902 5. When completed, the safety belt should look like the illustration. Safety Belt Twisted at Safety Belt Guide NOTE: These procedures apply to both wire-formed and stamped D-ring designs. 1. Grasp the belt webbing at the shoulder belt guide (D-ring). 2. Rotate and fold the belt webbing over itself to remove the twist. 3. Feed the folded portion of the belt through the safety belt guide (D-ring). 4. When completed, the safety belt should look like the illustration. Seat Belt With Anchor Plate Thread Damage 1. Remove the broken or stripped bolt and discard. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8903 2. Drill out the internal threads in the seat belt anchor plate with a 27/64-inch drill. 3. Rethread the anchor plate with a 1/2-13 tap (seat belt). 4. Blow out the chips. 5. Install the safety belt component(s). Parts Replacement Chart 6. Install a new bolt as specified in the Parts Replacement Chart. 7. Tighten the bolt(s) to 34-46 N.m (25-34 Lb/Ft). Seat Belt Without Anchor Plate Thread Damage Missing Weld Nut- Upper B-Pillar 1. Remove the interior trim panel to expose the suspect anchor point. 2. Determine if the weld nut only or the weld nut and reinforcement and weld nut are missing. If it is determined that the reinforcement is missing, install a reinforcement. To install a missing weld nut only, proceed to Step 3. 3. Obtain a M12 weld nut, and a standard washer. 4. Drill out two 8 mm (5/16 in) diameter holes adjacent to the clearance hole. 5. Obtain a length of copper welding wire and feed through clearance hole in door frame opening until it becomes visible at the access hole. 6. Pull wire through so that it may be secured to the weld nut and washer. 7. Pull wire back up to the weld nut clearance hole. 8. Hold weld nut securely in place and using Rotunda MIG Wire Feed Welder 106-00053 or equivalent, plug weld the nut in place at the two 8 mm (5/16 in) diameter holes previously drilled. 9. Metal finish as required. 10. Verify the nut is securely in place. Missing Weld Nut - Lower B-Pillar 1. Remove the interior trim panel to expose the suspect anchor point. 2. Obtain a M12 weld nut. 3. Drill two 8 mm (5/16 in) diameter holes adjacent to the clearance hole. 4. Align weld nut with the clearance hole using a piece of round stock. 5. Secure in place and using Rotunda MIG Wire Feed Welder 106-00053 or equivalent, plug weld at the two 8 mm (5/16 in) diameter holes previously drilled. 6. Metal finish as required. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8904 7. Verify the nut is securely in place. Shoulder Safety Belt Height Adjuster With Stripped Weld Nuts D-Ring Installation Kit Special Tool(s) Required 1. Remove the shoulder safety belt height adjuster. 2. Use the half-inch drill provided in the D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14 x 1.5 tap provided in the D-Ring Installation Kit, and tap new threads. NOTE: After each rotation, back off the tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert (part no. N807170-S190) provided in the D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 8905 5. Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several times to seat the insert keys. NOTE: Drive keys on the insert will act as an automatic stop. 6. Install the shoulder safety belt height adjuster. NOTE: If the shoulder safety belt height adjuster retaining bolts are stripped, replace the shoulder safety belt height adjuster and retaining bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications Seat Belt Buckle: Specifications Belt and Buckle Assembly, Pretensioner Bolt..................................................................................................................................34-46 N.m (25-34 Lb/Ft) Detachable Safety Belt Anchor Buckle End Bolt.............................................................................................................................34-46 N.m (25-34 Lb/Ft) Rear Buckle End Bolt........................................................................................................................... ...........................................34-46 N.m (25-34 Lb/Ft) Rear Safety Belt and Buckle Bolt......................................................................................................... ...........................................34-46 N.m (25-34 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair Seat Belt Buckle: Service and Repair Captain's Chair Safety Belt Bolt Bit Special Tool(s) Required Removal 1. Remove the buckle end. 1. Use the Safety Belt Bolt Bit to remove the buckle end bolt. 2. Remove the buckle end. Installation 1. Follow the removal procedure in reverse order. NOTE: Make sure to tighten bolts to specification shown in image(s). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8911 Seat Belt Buckle: Service and Repair Rear Seat Belt Buckle 3-Passenger Bench Seat Safety Belt Bolt Bit Special Tool(s) Required Removal 1. Use the Safety Belt Bolt Bit to remove the LH rear safety belt and buckle bolt. 2. Remove the LH rear safety belt and buckle. 3. Use the Safety Belt Bolt Bit to remove the RH rear safety belt and buckle bolt. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8912 4. Remove the RH rear safety belt and buckle. Installation 1. Follow the removal procedure in reverse order. - Check the restraint system for proper operation. NOTE: Make sure the safety belt webbing is not twisted prior to installation. - Make sure to tighten bolts to specification shown in image(s). 4-Passenger Bench Seat Safety Belt Bolt Bit Special Tool(s) Required Removal Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8913 1. Use the Safety Belt Bolt Bit to remove the LH rear safety belt and buckle bolt. 2. Remove the LH rear safety belt and buckle. 3. Use the Safety Belt Bolt Bit to remove the safety belt and tongue bolt. 4. Remove the safety belt and tongue. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8914 5. Use the Safety Belt Bolt Bit to remove the RH rear safety belt and buckle bolt. 6. Remove the RH rear safety belt and buckle. Installation 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8915 - Check the restraint system for proper operation. NOTE: Make sure the safety belt webbing is not twisted prior to installation. - Make sure to tighten bolts to specification shown in image(s). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8916 Seat Belt Buckle: Service and Repair Removal and Installation Safety Belt Bolt Bit Special Tool(s) Required Removal 1. On quad bucket captain chairs, remove the detachable safety belt anchor buckle end. 1. Use the Safety Belt Bolt Bit to remove the detachable safety belt anchor buckle end bolt. 2. Remove the detachable safety belt anchor buckle end. 2. On 3-passenger bench seats, remove the detachable safety belt anchor buckle end. 1. Use the Safety Belt Bolt Bit to remove the detachable safety belt anchor buckle end bolt. 2. Remove the detachable safety belt anchor buckle end. Installation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8917 1. Follow the removal procedure in reverse order. NOTE: Make sure to tighten bolts to specification shown in image(s). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation NOTE: There is a unique safety belt extension for the front seats and another unique safety belt extension for the rear seats. 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 through Ford or Lincoln-Mercury dealership parts departments. Safety belt extensions are available only with black webbing. The buckle must be from the same manufacturer as the belt system to which it is attached. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Specifications Seat Belt Height Adjuster: Specifications Shoulder Safety Belt Height Adjuster Bolts N.m.....................................................................................................................................34-46 (25-34 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation Seat Belt Height Adjuster: Service and Repair Removal and Installation Safety Belt Bolt Bit Special Tool(s) Required Removal 1. Remove the front seat shoulder strap guide cover. 2. Remove the shoulder strap guide. 1. Remove the shoulder strap guide nut. 2. Remove the shoulder strap guide. 3. On the driver side, remove the body side trim finish panel and the front upper body side trim panel. 4. On the passenger side, remove the center body pillar upper trim panel. 5. Remove the height adjuster cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 8926 6. Remove the shoulder safety belt height adjuster. 1. Use the Safety Belt Bolt Bit to remove the bolts. 2. Remove the shoulder safety belt height adjuster. Installation 1. Follow the removal procedure in reverse order. - Check the restraint system for proper operation. NOTE: Make sure the safety belt webbing is not twisted prior to installation. - Make sure to tighten bolts to specification shown in image(s). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 8927 Seat Belt Height Adjuster: Service and Repair Shoulder Safety Belt Height Adjuster With Stripped Weld Nuts D-Ring Installation Kit Special Tool(s) Required 1. Remove the shoulder safety belt height adjuster. 2. Use the half-inch drill provided in the D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14 x 1.5 tap provided in the D-Ring Installation Kit, and tap new threads. NOTE: After each rotation, back off the tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert (part no. N807170-S190) provided in the D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 8928 5. Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several times to seat the insert keys. NOTE: Drive keys on the insert will act as an automatic stop. 6. Install the shoulder safety belt height adjuster. NOTE: If the shoulder safety belt height adjuster retaining bolts are stripped, replace the shoulder safety belt height adjuster and retaining bolts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation The safety belt warning chime/buzzer reminds the driver to fasten the safety belt. This occurs when the ignition key is turned to RUN and the driver safety belt remains unbuckled. The chime/buzzer can be terminated by buckling the driver safety belt anytime during the 48 second chime/buzzer warning. The chime/buzzer works in conjunction with the safety belt warning indicator in the instrument cluster. When the ignition key is turned to RUN, the safety belt warning indicator will illuminate for five seconds, whether or not the driver safety belt is buckled, to perform a prove out on the bulb. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation The safety belt warning chime/buzzer reminds the driver to fasten the safety belt. This occurs when the ignition key is turned to RUN and the driver safety belt remains unbuckled. The chime/buzzer can be terminated by buckling the driver safety belt anytime during the 48 second chime/buzzer warning. The chime/buzzer works in conjunction with the safety belt warning indicator in the instrument cluster. When the ignition key is turned to RUN, the safety belt warning indicator will illuminate for five seconds, whether or not the driver safety belt is buckled, to perform a prove out on the bulb. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 98-3-10 > Feb > 98 > Seat Belt - Slow To Retract Seat Belt Retractor: Customer Interest Seat Belt - Slow To Retract Article No. 98-3-10 SEAT BELT-SLOW TO RETRACT LIGHT TRUCK: 1997-98 ECONOLINE ISSUE: The seat belts may be slow to retract on some vehicles. This may be caused by binding of the webbing or other conditions listed below. ACTION: Refer to the following Diagnostic Procedure to determine the cause of the seat belt being slow to retract. DIAGNOSTIC PROCEDURE 1. Follow the path of the webbing from the anchor to the retractor and verify the webbing does not rub against the interior trim panels. If it does, check the installation of the trim panel to make sure it is secured properly. 2. Check for any loose objects such as wiring rubbing against the webbing inside the B-pillar trim panel. If wiring is rubbing the webbing, secure the wiring away from the webbing. 3. Verify there is no binding on the webbing from the retractor cover. If the retractor cover is binding, then press on it from the top by the webbing slot to make sure it is snapped into the retractor frame. 4. Verify the D-ring is able to rotate freely around its mounting bolt. 5. Pull on the webbing where it exits the B-pillar trim and release. If it retracts quickly. then check for binding in the D-ring. If slow retraction seems to be caused by a tight gap binding the webbing in the D-ring, do not attempt to increase the clearance by applying sharp tools to the gap. In this situation, replace the belt and retractor assembly. CONVERSION VAN GUIDELINES 1. Make sure that no trim or any loose object comes in contact with the webbing between the retractor and the D-ring (inside or outside the B-pillar trim). 2. Make sure the webbing surface has not been altered during the conversion process (i.e., glue overspray or abrasion). 3. Make sure the D-ring's rotational movement ability is not restricted. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 98-3-10 > Feb > 98 > Seat Belt - Slow To Retract Seat Belt Retractor: All Technical Service Bulletins Seat Belt - Slow To Retract Article No. 98-3-10 SEAT BELT-SLOW TO RETRACT LIGHT TRUCK: 1997-98 ECONOLINE ISSUE: The seat belts may be slow to retract on some vehicles. This may be caused by binding of the webbing or other conditions listed below. ACTION: Refer to the following Diagnostic Procedure to determine the cause of the seat belt being slow to retract. DIAGNOSTIC PROCEDURE 1. Follow the path of the webbing from the anchor to the retractor and verify the webbing does not rub against the interior trim panels. If it does, check the installation of the trim panel to make sure it is secured properly. 2. Check for any loose objects such as wiring rubbing against the webbing inside the B-pillar trim panel. If wiring is rubbing the webbing, secure the wiring away from the webbing. 3. Verify there is no binding on the webbing from the retractor cover. If the retractor cover is binding, then press on it from the top by the webbing slot to make sure it is snapped into the retractor frame. 4. Verify the D-ring is able to rotate freely around its mounting bolt. 5. Pull on the webbing where it exits the B-pillar trim and release. If it retracts quickly. then check for binding in the D-ring. If slow retraction seems to be caused by a tight gap binding the webbing in the D-ring, do not attempt to increase the clearance by applying sharp tools to the gap. In this situation, replace the belt and retractor assembly. CONVERSION VAN GUIDELINES 1. Make sure that no trim or any loose object comes in contact with the webbing between the retractor and the D-ring (inside or outside the B-pillar trim). 2. Make sure the webbing surface has not been altered during the conversion process (i.e., glue overspray or abrasion). 3. Make sure the D-ring's rotational movement ability is not restricted. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 8948 Seat Belt Retractor: Specifications Safety Belt Retractor Bolts................................................................................................................... ............................................34-46 N.m (25-34 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 8949 Seat Belt Retractor: Description and Operation NOTE: The Automatic Locking Retractor (ALR) mode is not available on the driver safety belt. In the automatic locking retractor (ALR) mode, the shoulder belt is automatically pre-locked. However, the belt will still retract to remove any slack in the shoulder belt. This mode is used any time a child safety seat is installed in an outboard seating position, or when a tight lap/shoulder belt fit is desired. The ALR mode is automatically engaged when the webbing is fully extracted from the retractor. As the webbing is retracted back onto the spool, an audible clicking sound is made, indicating that the retractor is in the ALR mode. The ALR mode is automatically disengaged when the webbing is retracted back onto the spool. ALR mode is disengaged when the audible clicking sound ceases and the webbing is free to move in or out of the retractor, indicating that the belt has returned to the vehicle sensitive (emergency) locking mode of operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue Seat Belt Retractor: Service and Repair Front Seat Belt, Retractor and Tongue Safety Belt Bolt Bit Special Tool(s) Required Removal NOTE: Safety belt buckles, pyrotechnic safety belt buckle pretensioners, height adjusters, center adjust tongues and belts and retractors can be replaced separately. However, if a safety belt assembly was in use during a collision, the belt and retractor must be replaced as well as the center adjust tongue and belt and buckle assembly or the center adjust tongue and the cable and buckle assembly. When replacing safety belts and buckles, pyrotechnic safety belt buckle pretensioners, height adjusters, safety cables and buckles, center adjust tongues and belts and retractors, use only the replacement parts specified in the Ford Master Parts Catalogs for the make and model of the vehicle being serviced. Safety belt assemblies must not be interchanged between vehicle models. 1. Remove the front seat shoulder strap guide cover. 2. Remove the shoulder strap guide. 1. Remove the shoulder strap guide nut. 2. Remove the shoulder strap guide. 3. On the driver side, remove the front door scuff plate, the body side trim finish panel, the front upper body side trim panel, and the front lower body side trim panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 8952 4. Remove the front safety belt retractor. 1. Use the Safety Belt Bolt Bit to remove the bolt. 2. Remove the front safety belt retractor. 5. On the driver side, remove the front safety belt anchor. 1. Use the Safety Belt Bolt Bit to remove the bolt. 2. Remove the front safety belt anchor. 6. On the passenger side, remove the front door scuff plate, the center body pillar upper trim panel and the center body pillar lower trim panel. 7. Remove the front safety belt retractor and the front safety belt anchor. 1. Use the Safety Belt Bolt Bit to remove the retractor bolt. 2. Remove the front safety belt retractor. 3. Use the Safety Belt Bolt Bit to remove the anchor bolt. 4. Remove the front safety belt anchor. Installation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 8953 1. Follow the removal procedure in reverse order. - Check the restraint system for proper operation. NOTE: - Make sure the safety belt webbing is not twisted prior to installation. - Make sure to tighten bolts to specification shown in image(s). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 8954 Seat Belt Retractor: Service and Repair Rear Seats Safety Belt Bolt Bit Special Tool(s) Required Removal 1. On a rear safety belt retractor and tongue with a flip-up shoulder strap guide cover, remove the shoulder strap guide as follows. 1. Lift the shoulder strap guide cover. 2. Use the Safety Belt Bolt Bit to remove the bolt. 3. Remove the shoulder strap guide. 2. On a rear safety belt retractor and tongue without a flip-up shoulder strap guide cover, remove the shoulder strap guide as follows. 1. Position the shoulder strap guide cover aside. 2. Use the Safety Belt Bolt Bit to remove the bolt. 3. Remove the shoulder strap guide. 3. On the LH second row rear safety belt retractor and tongue, remove the quarter trim finish panel, the body side rear center lower trim panel and the quarter trim panel. 4. On the LH third, fourth and fifth row rear safety belt retractor and tongues, remove the quarter trim rear upper panel and the quarter trim rear lower panel. 5. On the RH rear safety belt retractor and tongue, remove the quarter trim upper panel, the quarter trim lower panel, the quarter trim rear upper panel and the body side trim cover rear. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 8955 6. Remove the safety belt retractor. 1. Remove the safety belt guide. 2. Use the Safety Belt Bolt Bit to remove the bolt. 3. Remove the safety belt retractor. 7. On a rear safety belt retractor and tongue with a detachable safety belt anchor, disengage the detachable safety belt anchor. 1. Insert a key or small screwdriver into the slot in the detachable anchor and lift upward. 2. Disengage the detachable anchor tongue end from the detachable anchor. 8. On a rear safety belt retractor and tongue without a detachable safety belt anchor, remove the safety belt anchor. 1. Use the Safety Belt Bolt Bit to remove the bolt. 2. Remove the safety belt anchor. Installation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 8956 1. Follow the removal procedure in reverse order. - Check the restraint system for proper operation. NOTE: Make sure the safety belt webbing is not twisted prior to installation. - Make sure to tighten bolts to specification shown in image(s). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Specifications Seat Belt Tensioner: Specifications Belt and Buckle Assembly, Pretensioner Bolt..................................................................................................................................34-46 N.m (25-34 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Diagram Information and Instructions Seat Belt Tensioner: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Diagram Information and Instructions > Page 8962 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Diagram Information and Instructions > Page 8963 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Diagram Information and Instructions > Page 8964 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Diagram Information and Instructions > Page 8965 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Diagram Information and Instructions > Page 8966 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Diagram Information and Instructions > Page 8967 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Diagram Information and Instructions > Page 8968 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Diagram Information and Instructions > Page 8969 Belt And Buckle Assembly (Pretensioner) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 8970 Seat Belt Tensioner: Description and Operation The belt and buckle assembly pretensioner is a pyrotechnic device that removes excess webbing from the safety belt system. The belt and buckle assembly pretensioner uses the same crash sensor system as the air bag Supplemental Restraint System (SRS). When the belt and buckle assembly pretensioner deploys, the buckle moves downward, pulling excess webbing from the lap and shoulder safety belts. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 8971 Seat Belt Tensioner: Service and Repair Safety Belt Bolt Bit Special Tool(s) Required Removal WARNING: - THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG-EQUIPPED VEHICLE AND WHEN HANDLING A BELT AND BUCKLE ASSEMBLY PRETENSIONER. - THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. NEVER PROBE THE CONNECTORS ON THE BELT AND BUCKLE ASSEMBLY PRETENSIONERS. DOING SO COULD RESULT IN BELT AND BUCKLE ASSEMBLY PRETENSIONER OR AIR BAG DEPLOYMENT AND COULD RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Disconnect the battery ground cable. On vehicles equipped with dual batteries: Disconnect the secondary positive cable from the primary battery terminal. Wrap secondary positive cable with non-conductive material to insulate it. NOTE: Make sure the tool does not contact any ground surface. The secondary battery positive cable remains energized after disconnection. - Disconnect primary battery ground cable - Disconnect primary battery positive cable. NOTE: Failure to accurately follow the battery disconnect procedures will result in vehicle or component damage. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. On the driver side, remove the front seat back latch lower cover. 3. On the passenger side, remove the front seat back pivot side outer cover. 4. Remove the belt and buckle assembly pretensioner. 1. Disconnect the belt and buckle assembly pretensioner harness connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 8972 2. Using the Safety Belt Bolt Bit, remove the belt and buckle assembly pretensioner retaining bolt. 3. Remove the belt and buckle assembly pretensioner. Installation WARNING: - THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG-EQUIPPED VEHICLE AND WHEN HANDLING A BELT AND BUCKLE ASSEMBLY PRETENSIONER. - THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. NEVER PROBE THE CONNECTORS ON THE BELT AND BUCKLE ASSEMBLY PRETENSIONERS. DOING SO COULD RESULT IN BELT AND BUCKLE ASSEMBLY PRETENSIONER OR AIR BAG DEPLOYMENT AND COULD RESULT IN PERSONAL INJURY. 1. Follow the removal procedure in reverse order. Align both anti-rotation tabs on the belt and buckle assembly pretensioner into the seat track prior to tightening the bolt. 2. Reconnect negative battery cable. On vehicles equipped with dual batteries: - Reconnect primary battery terminal connections. - Reconnect positive battery cable. - Reconnect the negative battery cable. - Unwrap the secondary battery positive cable and reconnect it to the primary battery positive terminal. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module ( PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. - Make sure to tighten bolts to specification shown in image(s). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information > Description and Operation Seat Belt Warning Timer: Description and Operation The driver safety belt incorporates a safety belt warning indicator switch, an indicator light and warning chime. The indicator light and warning chime function as reminders to fasten the safety belt. The safety belt indicator light illuminates in the instrument cluster and a warning chime sounds to remind the occupants to fasten their safety belts. The conditions of operation are as follows: - If the driver safety belt is not buckled before the ignition key is turned to the ON position, the safety belt indicator light illuminates for 1-2 minutes and the warning chime sounds for 4-8 seconds. - If the driver safety belt is buckled while the indicator light is illuminated and the warning chime is sounding, the safety belt indicator light and the warning chime turn off. - If the driver safety belt is buckled before the ignition key is turned to the ON position, the safety belt indicator light and warning chime remain off. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Primary Crash Sensor Screws............................................................................................................. ...............................................11-13 N.m (8-10 Lb/Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 8980 Impact Sensor: Locations Engine Compartment Views The Center Air Bag Sensor is located in front center of the engine compartment, behind grille. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 8981 Impact Sensor: Description and Operation WARNING: THE ECS AND PRIMARY CRASH SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION WHERE THE RADIATOR GRILLE, FRAME RAILS OR RIGHT COWL PANEL HAS BEEN DAMAGED, INSPECT THE MOUNTINGS AND BRACKETS FOR DEFORMATION. IF DAMAGED, THE PRIMARY CRASH SENSOR OR ECS MUST BE REPLACED WHETHER OR NOT THE AIR BAG MODULES HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE PRIMARY CRASH SENSOR MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. NOTE: - The safing sensor is internal to the ECS and is not serviced separately. - If the primary crash sensor is undamaged after a collision, it will automatically reset and can be reused. The SRS contains three sensors located in the following spots: - the ECS, mounted behind the RH cowl side trim panel. - the primary crash sensor mounted on the center radiator support. - the safing sensor, which is internal to the ECS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 8982 Impact Sensor: Service and Repair Removal WARNING: - VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, REPLACE THE SENSOR WHETHER OR NOT THE AIR BAG IS DEPLOYED. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: Repair is made by replacement only. If a part is replaced and the new part does not correct the condition install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable(s). 2. Remove the radiator grille. 3. Disconnect the primary crash sensor electrical connector. 4. Remove the primary crash sensor. 1. Remove the screws. 2. Remove the primary crash sensor. Installation WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. IF DAMAGED, REPLACE THE SENSOR WHETHER OR NOT THE AIR BAG IS DEPLOYED. NOTE: Repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 8983 1. Follow the Removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications Antenna: Specifications Antenna Base Screws ......................................................................................................................... ................................................. 1.6-2.2 Nm (18 Lb-In) Fender Splash Shield Screws ........................ ......................................................................................................................................... 1-2 Nm (9-18 Lb-In) Radio Antenna Mast ........................................................................................................ ............................................................... 3.4-3.6 Nm (27-35 Lb-In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 8988 Antenna: Description and Operation Antenna The antenna and related components consist of the following: - Radio antenna mast. - Radio antenna lead in cable. - Fender-mounted antenna base. The antenna receives AM and FM radio frequency waves. These radio frequency waves are sent to the radio chassis through the radio antenna lead in cable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 8989 Antenna: Service and Repair REMOVAL 1. Remove the radio antenna mast from the antenna base. 2. Remove the antenna base. 1 Remove the radio antenna base cap. 2 Remove the screws. 3 Lift the antenna base. 4 Disconnect the radio antenna lead in cable from the antenna base and remove the antenna base. 3. Remove the fender splash shield. 1 Remove the screws. 2 Remove the pushpin and remove the fender splash shield. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 8990 4. Push the (A) radio antenna lead in cable and the (B) grommet into the passenger compartment. 5. Remove the instrument panel finish panel. 6. Remove the cowl side trim panel. 7. Locate and follow the radio antenna lead in cable from end to end, and disconnect the retainers from the wiring harness and the wiring harness trough. 8. Remove the radio chassis. 9. Remove the radio antenna lead in cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: Customer Interest Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9001 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9002 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: All Technical Service Bulletins Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9008 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9009 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9010 Keyless Entry Module: Locations Full Body Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9011 The Remote Keyless Entry (RKE) module with integral receiver is located behind the B-pillar on the driver side. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9012 Keyless Entry Module: Diagrams Remote Keyless Entry Module (C335) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9013 Remote Keyless Entry Module (C336) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9014 Keyless Entry Module: Description and Operation The Remote Keyless Entry (RKE) module performs the following functions: - Unlocks the driver front door. - Unlocks all doors. - Locks all doors. - Turns on the interior lamps after either front door handle is lifted. - Turns on the interior lamps when using a keyless entry remote transmitter. - Activates and deactivates a personal security panic alarm feature that sounds the horn and flashes the parking lamps and headlamps. - Activates the lock verify feature that sounds the horn when the lock button is pressed on the keyless entry remote transmitter twice within five seconds. - Remembers to lock the sliding door if the door locks are activated when the sliding door is open. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Programming Procedure Keyless Entry Module: Service and Repair Programming Procedure Programming - Keyless Entry Remote Transmitter NOTE: To program (or reprogram) a keyless entry remote transmitter into the Remote Keyless Entry (RKE) module, perform the following steps: 1. Turn the key to the RUN or ACC position and short the two terminals of the program connector, a two-pin connector located at the base of the steering column connected to the ignition switch wiring harness. All doors should lock and then unlock. 2. Press any button on each keyless entry remote transmitter in turn. All doors should lock and then unlock. If the door locks do not respond, press the button again (up to three times maximum with the same keyless entry remote transmitter). 3. Repeat Step 2 to program additional keyless entry remote transmitters into the RKE module (up to four keyless entry remote transmitters maximum). 4. Turn the key off. 5. Remove the short from the program connector. All doors should lock and then unlock. 6. Verify that the keyless entry remote transmitters have been successfully programmed by pressing the lock or unlock button on each one, and observing that the system responds by locking and unlocking the doors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Programming Procedure > Page 9017 Keyless Entry Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the body side trim finish panel. 1 Remove the three finish panel pushpins. 2 Remove the finish panel from the body side. 3. Remove the remote keyless entry module. 1 Disconnect the electrical connectors. 2 Remove the two nuts. 3 Remove the module. INSTALLATION 1. To install, reverse the removal procedure. - If installing a new module it is necessary to reprogram Remote Keyless Entry Transmitters. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Programming Connector > Component Information > Locations Keyless Entry Programming Connector: Locations A two-pin connector located at the base of the steering column connected to the ignition switch wiring harness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Transmitter: Customer Interest Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9029 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9030 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9036 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9037 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 9038 Keyless Entry Transmitter: Description and Operation The electronic door lock control system is supplied with two, three-button, hand-held keyless entry remote transmitters. The keyless entry remote transmitters have three different shaped buttons, with icons used to identify the lock, unlock and panic features. NOTE: The electronic door lock control features will not function when the key is in run or accessory. To unlock the driver front door, press the unlock button once on a keyless entry remote transmitter that has been programmed into the RKE module. To unlock all doors, press the unlock button on a keyless entry remote transmitter twice. The second press must be within five seconds of the first. If more than five seconds have elapsed since the first press of the unlock button, pressing the unlock button again will only unlock the driver front door. To turn on the interior lamps, press the unlock button. To lock all doors, press the lock button on a keyless entry remote transmitter once. If the sliding door was open during the lock operation, the memory lock feature will activate to lock the sliding door after it is closed again. Pressing the lock button a second time within five seconds will lock the locks again and activate the lock verify feature which will provide a chirp" from the horn. To activate the personal security alarm, press the panic button on a transmitter. The horn will sound and the parking lamps and headlamps will flash for a Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 9039 maximum of three minutes. Activating the panic alarm also illuminates the interior lamps. To deactivate the personal security alarm, press the panic button on the same keyless entry remote transmitter that was used to activate the alarm, or turn the key on. The RKE module will erase all previous keyless entry remote transmitters from memory when the keyless entry remote transmitters are programmed or reprogrammed. NOTE: The RKE module can store up to four keyless entry remote transmitters in memory. When troubleshooting the electronic door lock control system, it is essential that the customer leaves at least one keyless entry remote transmitter with the vehicle. If the customer has purchased additional keyless entry remote transmitters, lost one, or if one must be reprogrammed into the RKE module, all keyless entry remote transmitters must be available for reprogramming at the same time. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 9040 Keyless Entry Transmitter: Service and Repair Programming - Keyless Entry Remote Transmitter NOTE: To program (or reprogram) a keyless entry remote transmitter into the Remote Keyless Entry (RKE) module, perform the following steps: 1. Turn the key to the RUN or ACC position and short the two terminals of the program connector, a two-pin connector located at the base of the steering column connected to the ignition switch wiring harness. All doors should lock and then unlock. 2. Press any button on each keyless entry remote transmitter in turn. All doors should lock and then unlock. If the door locks do not respond, press the button again (up to three times maximum with the same keyless entry remote transmitter). 3. Repeat Step 2 to program additional keyless entry remote transmitters into the RKE module (up to four keyless entry remote transmitters maximum). 4. Turn the key off. 5. Remove the short from the program connector. All doors should lock and then unlock. 6. Verify that the keyless entry remote transmitters have been successfully programmed by pressing the lock or unlock button on each one, and observing that the system responds by locking and unlocking the doors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9051 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9052 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9053 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9054 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9055 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9056 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9057 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9063 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9064 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9065 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9066 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9067 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9068 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9069 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 9070 Radio/Stereo Noise Filter: Specifications Body Ground Strap Screw ................................................................................................................... .............................................. 7-10 Nm (62-89 Lb-In) Frame Rail Ground Strap Screw ...................................................................................................................................................... 15-20 Nm (11-15 Lb-Ft) Generator Ground Strap Nut ................................................................................................................................................... 25.9-34.9 Nm (19-25.6 Lb-Ft) Radio Ignition Interference Capacitor Screw ..................................................................................................................................... 7-10 Nm (62-89 Lb-In) Cowl Ground Strap Screw .............................................................................................................................................................. 1.7-4.7 Nm (15-41 Lb-In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 9071 Radio/Stereo Noise Filter: Description and Operation The radio suppression equipment reduces interference transmitted through the radio speakers by the engine ignition and electrical systems. When replacing any radio suppression equipment components, make sure that a good contact is made at all connections. Remove any paint or dirt from between a component and its ground. Tighten all connectors and screws securely according to torque specifications. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers Speaker: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9080 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9081 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9082 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9083 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9084 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9085 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9086 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Speaker: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9092 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9093 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9094 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9095 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9096 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9097 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9098 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 9099 Speaker: Specifications Radio Speaker Screws ........................................................................................................................ .................................................. 4-5 Nm (35-44 Lb-In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 9100 Speaker: Description and Operation Speaker Locations Depending on trim level, these vehicles may be equipped with up to six radio speakers. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 9101 Speaker: Service and Repair DOOR MOUNTED SPEAKERS REMOVAL 1. Remove the door trim panel. 2. Remove the speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Description and Operation Tape Player: Description and Operation M100 AM/FM Cassette Radio With Clock P100i Premium AM/FM Cassette Radio With Clock Depending on vehicle trim level, the audio system will have two, four or six radio speakers. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Service and Repair > Cassette Tape Player Head Cleaning Tape Player: Service and Repair Cassette Tape Player Head Cleaning 1. For best performance, it is recommended that the tape player be cleaned after every 10-12 hours of playing time. The tape player should be cleaned using a Ford tape player cleaning cartridge, available at your Ford dealer. The use of other cleaning products is not recommended, as these products could cause damage to the tape player or cassette tapes. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Service and Repair > Cassette Tape Player Head Cleaning > Page 9107 Tape Player: Service and Repair Removal and Installation Radio Removing Tool Special Tool(s) REMOVAL NOTE: The following removal and installation procedures apply to all original equipment radio chassis. 1. Disconnect the battery ground cable. 2. Remove the radio chassis. - Insert Radio Removal Tool into the radio face plate, release the radio retaining clips and pull outward on Radio Removal Tool while pulling the radio chassis away from the instrument panel. 3. Disconnect the radio antenna lead in cable and the radio electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: Customer Interest Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9117 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9118 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: All Technical Service Bulletins Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9124 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9125 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9126 Keyless Entry Module: Locations Full Body Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9127 The Remote Keyless Entry (RKE) module with integral receiver is located behind the B-pillar on the driver side. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9128 Keyless Entry Module: Diagrams Remote Keyless Entry Module (C335) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9129 Remote Keyless Entry Module (C336) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9130 Keyless Entry Module: Description and Operation The Remote Keyless Entry (RKE) module performs the following functions: - Unlocks the driver front door. - Unlocks all doors. - Locks all doors. - Turns on the interior lamps after either front door handle is lifted. - Turns on the interior lamps when using a keyless entry remote transmitter. - Activates and deactivates a personal security panic alarm feature that sounds the horn and flashes the parking lamps and headlamps. - Activates the lock verify feature that sounds the horn when the lock button is pressed on the keyless entry remote transmitter twice within five seconds. - Remembers to lock the sliding door if the door locks are activated when the sliding door is open. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Programming Procedure Keyless Entry Module: Service and Repair Programming Procedure Programming - Keyless Entry Remote Transmitter NOTE: To program (or reprogram) a keyless entry remote transmitter into the Remote Keyless Entry (RKE) module, perform the following steps: 1. Turn the key to the RUN or ACC position and short the two terminals of the program connector, a two-pin connector located at the base of the steering column connected to the ignition switch wiring harness. All doors should lock and then unlock. 2. Press any button on each keyless entry remote transmitter in turn. All doors should lock and then unlock. If the door locks do not respond, press the button again (up to three times maximum with the same keyless entry remote transmitter). 3. Repeat Step 2 to program additional keyless entry remote transmitters into the RKE module (up to four keyless entry remote transmitters maximum). 4. Turn the key off. 5. Remove the short from the program connector. All doors should lock and then unlock. 6. Verify that the keyless entry remote transmitters have been successfully programmed by pressing the lock or unlock button on each one, and observing that the system responds by locking and unlocking the doors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Programming Procedure > Page 9133 Keyless Entry Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the body side trim finish panel. 1 Remove the three finish panel pushpins. 2 Remove the finish panel from the body side. 3. Remove the remote keyless entry module. 1 Disconnect the electrical connectors. 2 Remove the two nuts. 3 Remove the module. INSTALLATION 1. To install, reverse the removal procedure. - If installing a new module it is necessary to reprogram Remote Keyless Entry Transmitters. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9139 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9140 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9141 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9142 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9143 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9144 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9145 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9146 Trailer Connector: Connector Views Electronic Brake Modified Vehicle Power (C233) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9147 Modified Vehicle Power (C331) Trailer/Camper Adapter (Class II) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9148 Trailer Connector: Electrical Diagrams With Auxiliary Battery Trailer/Camper Adapter - With Auxiliary Battery Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9149 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9150 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9151 Trailer/Camper Adapter Without Auxiliary Battery Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9152 Trailer/Camper Adapter - Without Auxiliary Battery Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9153 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9154 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9155 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9160 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9161 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9162 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9163 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9164 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9165 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9166 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9167 Trailer Lamps: Electrical Diagrams Trailer/Camper Adapter - With Auxiliary Battery Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9168 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9169 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9170 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9171 Trailer/Camper Adapter - Without Auxiliary Battery Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9172 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9173 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9174 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis Trailer Lamps: Flow of Diagnosis 1. Check the trailer feed wiring and the added trailer connector for obvious signs of damage. 2. Check the fuses and relays for damage. 3. If the concern remains after the inspection, determine the symptom(s) and proceed to the symptom chart. See: Symptom Related Diagnostic Procedures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9177 Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Check the trailer feed wiring and the added trailer connector for obvious signs of damage. 2. Check the fuses and relays for damage. 3. If the concern remains after the inspection, determine the symptom(s) and proceed to the symptom chart. See: Symptom Related Diagnostic Procedures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9178 73 Digital Multimeter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9179 Trailer Lamps: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9180 AA1 - AA2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9181 AA3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9182 W1 - W2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9183 X1 - X2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9184 Y1 - Y3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9185 Y4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9186 Z1 - Z2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9187 Z3 - Z4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9188 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations The trailer lamp relays are located in the Engine Compartment Fuse Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay Trailer Backup Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 9194 Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 9195 Trailer Running Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9200 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9201 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9202 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9203 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9204 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9205 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9206 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9207 Trailer Connector: Connector Views Electronic Brake Modified Vehicle Power (C233) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9208 Modified Vehicle Power (C331) Trailer/Camper Adapter (Class II) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9209 Trailer Connector: Electrical Diagrams With Auxiliary Battery Trailer/Camper Adapter - With Auxiliary Battery Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9210 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9211 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9212 Trailer/Camper Adapter Without Auxiliary Battery Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9213 Trailer/Camper Adapter - Without Auxiliary Battery Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9214 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9215 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9216 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 REMOVAL Remove the outside door handle. 1 Drill out the rivets. 2 Disconnect the outside door handle-to-latch rod. 3 Remove the outside door handle. INSTALLATION Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip Front Door Panel: Technical Service Bulletins Interior Door Trim Panel - Replacement Tip Article No. 99-8-15 05/03/99 INTERIOR TRIM - DOOR TRIM PANEL REPLACEMENT - SERVICE TIP FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2 LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999 F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel. ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the door trim panel. Use the Quick Reference Guide at the end of this article to determine the type of fastener used for the vehicle being worked on. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 9229 For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment Scheme Chart to identify vehicles with molded hook designs. WARNING REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANEL. Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01-05/501-05. OTHER APPLICABLE ARTICLES: NONE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 9230 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair Heavy Duty Riverter Special Tool(s) REMOVAL WARNING: ALWAYS WEAR SAFETY GLASSES AND GLOVES WHEN HANDLING GLASS TO AVOID PERSONAL INJURY. 1. Remove the front door trim panel. 2. Remove the front door belt line inside weatherstrip. 3. Remove the rear glass channel bolt, and lift the channel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Page 9234 4. Lower the window glass to gain access to the two glass bracket retaining rivets. 5. Remove the center pins from the rivets, using a drift. Using a 1/4-inch diameter drill, drill out the remainder of the rivets. CAUTION: Do not attempt to pry out the rivets, as damage to the front door window glass can result. Prior to removing the rivet center pins, it is recommended that a suitable block support be placed between the front door outer panel and the glass bracket to stabilize the glass during rivet removal. 6. Lift up and rotate the front door window glass clockwise, and remove. INSTALLATION 1. Follow the removal procedure in reverse order. - Use the Heavy Duty Riveter to install the rivets (W525172-S). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Heavy Duty Riverter Special Tool(s) REMOVAL 1. Remove the front door window glass. 2. Remove the window regulator electric drive (if so equipped). 3. Remove the center pins from the rivets, using a drift. Using a 1/4-inch diameter drill, drill out the rivets attaching the window regulator lower bracket to the inner panel. NOTE: Use care not to enlarge the sheet metal holes in the door inner panel. 4. Remove the nuts retaining the window regulator upper bracket to the door inner panel. 5. Remove the window regulator. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 9238 1. Follow the removal procedure in reverse order. - Use the Heavy Duty Riveter to install the rivets (W525172-S). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip Rear Door Panel: Technical Service Bulletins Interior Door Trim Panel - Replacement Tip Article No. 99-8-15 05/03/99 INTERIOR TRIM - DOOR TRIM PANEL REPLACEMENT - SERVICE TIP FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2 LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999 F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel. ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the door trim panel. Use the Quick Reference Guide at the end of this article to determine the type of fastener used for the vehicle being worked on. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 9244 For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment Scheme Chart to identify vehicles with molded hook designs. WARNING REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANEL. Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01-05/501-05. OTHER APPLICABLE ARTICLES: NONE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 9245 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Window Regulator Bracket Upper Nuts ......................................................................................................................................... 8-14 Nm (71-124 Lb-In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Service and Repair Sliding Door Handle: Service and Repair Handle-Single Latch or Sliding Door, Outside Removal 1. Remove the door trim and watershield. 2. Front door and sliding door: disconnect the outside door handle-to-latch rod from the retaining clip. 3. Right rear door: remove the licence plate housing screws and pull the housing away from the door. 4. Right side hinged and right rear door: disconnect the cable from the door handle lever. 5. All doors except sliding door: drill out the rivets and remove the door handle. 6. Sliding door: remove the nuts and remove the door handle. Installation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Service and Repair > Page 9253 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9259 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9260 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9261 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9262 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9263 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 01-11-9 > Jun > 01 > Frame - Creaking Noise/Cracked Cross-Member: Customer Interest Frame - Creaking Noise/Cracked Article No. 01-11-9 06/11/01 ^ FRAME - CRACKS IN RIGHT REAR # 1 CROSSMEMBER - VEHICLES WITH HIGH ODOMETER READING OR SEVERE SERVICE VEHICLES PRODUCED BEFORE 2/6/2001 ^ NOISE - "CREAKING" WHILE TURNING WHEEL OR DRIVING OVER UNEVEN SURFACES VEHICLES WITH HIGH ODOMETER READING OR SEVERE SERVICE - VEHICLES PRODUCED BEFORE 2/6/2001 FORD: 1997-2001 E SERIES, ECONOLINE This article is being republished in its entirety to update the model year coverage. ISSUE A "creaking" noise may be heard when turning wheel or driving over uneven surfaces on vehicles produced before 2/6/2001. This may be due to a crack on the right rear side of the # 1 crossmember. The crack may start from where the right rear attaching tab for the spring tower is located. ACTION Clean and weld the affected area including welding around the right rear attaching tab for the spring tower. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect right rear of the # 1 crossmember (Figure 1 - General Area) for any signs of a crack. 2. If a crack is NOT found, proceed with normal Noise/Vibration/Harshness (NVH) diagnostics. If any crack is found, begin by cleaning the area to be welded completely. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 01-11-9 > Jun > 01 > Frame - Creaking Noise/Cracked > Page 9273 3. Drill holes at the end of the crack to prevent crack expansion. 4. V-grind the crack to ensure proper weld penetration. 5. Use clamps/jacks as necessary to align both sides of the crack. NOTE BE SURE THAT TEMPERATURE OF THE METAL DOES NOT EXCEED 760°C (1400°F) DURING WELDING. 6. Weld both sides of the affected areas where possible. 7. Weld around the edge of the right rear attaching tab for the spring tower to the # 1 crossmember of the frame (Figure 1, View A). DO NOT weld the rivet. 8. Clean off weld flash/scale and paint welded sections of the frame. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-14-11 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 305000, 390000, 702000, 702100 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 01-11-9 > Jun > 01 > Frame - Creaking Noise/Cracked Cross-Member: All Technical Service Bulletins Frame - Creaking Noise/Cracked Article No. 01-11-9 06/11/01 ^ FRAME - CRACKS IN RIGHT REAR # 1 CROSSMEMBER - VEHICLES WITH HIGH ODOMETER READING OR SEVERE SERVICE VEHICLES PRODUCED BEFORE 2/6/2001 ^ NOISE - "CREAKING" WHILE TURNING WHEEL OR DRIVING OVER UNEVEN SURFACES VEHICLES WITH HIGH ODOMETER READING OR SEVERE SERVICE - VEHICLES PRODUCED BEFORE 2/6/2001 FORD: 1997-2001 E SERIES, ECONOLINE This article is being republished in its entirety to update the model year coverage. ISSUE A "creaking" noise may be heard when turning wheel or driving over uneven surfaces on vehicles produced before 2/6/2001. This may be due to a crack on the right rear side of the # 1 crossmember. The crack may start from where the right rear attaching tab for the spring tower is located. ACTION Clean and weld the affected area including welding around the right rear attaching tab for the spring tower. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect right rear of the # 1 crossmember (Figure 1 - General Area) for any signs of a crack. 2. If a crack is NOT found, proceed with normal Noise/Vibration/Harshness (NVH) diagnostics. If any crack is found, begin by cleaning the area to be welded completely. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 01-11-9 > Jun > 01 > Frame - Creaking Noise/Cracked > Page 9279 3. Drill holes at the end of the crack to prevent crack expansion. 4. V-grind the crack to ensure proper weld penetration. 5. Use clamps/jacks as necessary to align both sides of the crack. NOTE BE SURE THAT TEMPERATURE OF THE METAL DOES NOT EXCEED 760°C (1400°F) DURING WELDING. 6. Weld both sides of the affected areas where possible. 7. Weld around the edge of the right rear attaching tab for the spring tower to the # 1 crossmember of the frame (Figure 1, View A). DO NOT weld the rivet. 8. Clean off weld flash/scale and paint welded sections of the frame. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-14-11 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 305000, 390000, 702000, 702100 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect the battery ground cable(s). WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable(s). REACTIVATION PROCEDURE 1. Disconnect the battery ground cables. WARNING: THE AIR BAG SIMULATORS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Reconnect the passenger air bag module. 7. Reconnect the battery ground cable(s). 8. Prove out the system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 9289 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the primary crash sensor connected and mounted to the vehicle? [ ] 2. Is the three-way connector at the base of the steering column connected? [ ] 3. Are the air bag modules and belt and buckle assembly pretensioners or air bag simulators connected? [ ] 4. Is the air bag Electronic Crash Sensor (ECS) module connected? [ ] 5. Is the vehicle battery connected? [ ] Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Technical Service Bulletins > Customer Interest for Scuff Plate: > 99-18-11 > Sep > 99 > Front Passenger Side Stepwell Cover - Not Flush Scuff Plate: Customer Interest Front Passenger Side Stepwell Cover - Not Flush Article No. 99-18-11 09/06/99 BODY - FRONT PASSENGER SIDE STEPWELL COVER NOT FLUSH - SERVICE TIP FORD: 1997-1999 ECONOLINE ISSUE The rearmost portion of the front passenger side stepwell cover may not sit flush over the side passenger/cargo door stepwell cover at the B-pillar if the side passenger/cargo door stepwell cover is replaced with new service parts that were built after 8/1/1999. This may be due to a tooling change in the side passenger/cargo door stepwell cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Technical Service Bulletins > Customer Interest for Scuff Plate: > 99-18-11 > Sep > 99 > Front Passenger Side Stepwell Cover - Not Flush > Page 9298 ACTION Check the rear of the front passenger side stepwell cover for a plastic positioning tab at the rear (Figure 1). If plastic positioning tab is present, eliminate the interference between the stepwells at the right B-pillar by removing the round plastic positioning tab from the rear of the front passenger side stepwell cover (Figure 2). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 107000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Scuff Plate: > 99-18-11 > Sep > 99 > Front Passenger Side Stepwell Cover - Not Flush Scuff Plate: All Technical Service Bulletins Front Passenger Side Stepwell Cover - Not Flush Article No. 99-18-11 09/06/99 BODY - FRONT PASSENGER SIDE STEPWELL COVER NOT FLUSH - SERVICE TIP FORD: 1997-1999 ECONOLINE ISSUE The rearmost portion of the front passenger side stepwell cover may not sit flush over the side passenger/cargo door stepwell cover at the B-pillar if the side passenger/cargo door stepwell cover is replaced with new service parts that were built after 8/1/1999. This may be due to a tooling change in the side passenger/cargo door stepwell cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Scuff Plate: > 99-18-11 > Sep > 99 > Front Passenger Side Stepwell Cover - Not Flush > Page 9304 ACTION Check the rear of the front passenger side stepwell cover for a plastic positioning tab at the rear (Figure 1). If plastic positioning tab is present, eliminate the interference between the stepwells at the right B-pillar by removing the round plastic positioning tab from the rear of the front passenger side stepwell cover (Figure 2). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 107000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair Trim Panel: Service and Repair REMOVAL 1. Remove the door handle bezel. 2. Remove the power window/door lock switch bezel, if so equipped. 3. Remove the rearview mirror fastener trim cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Page 9308 4. Remove the door panel trim retaining screws. 5. Lift the door trim panel up from the door to disengage the trim panel clips. 6. Remove the courtesy lamp wiring harness connector and remove the door trim panel. INSTALLATION Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Door Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9315 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9316 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9317 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9318 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9319 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: Customer Interest Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9329 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9330 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: All Technical Service Bulletins Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9336 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9337 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9338 Keyless Entry Module: Locations Full Body Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9339 The Remote Keyless Entry (RKE) module with integral receiver is located behind the B-pillar on the driver side. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9340 Keyless Entry Module: Diagrams Remote Keyless Entry Module (C335) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9341 Remote Keyless Entry Module (C336) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9342 Keyless Entry Module: Description and Operation The Remote Keyless Entry (RKE) module performs the following functions: - Unlocks the driver front door. - Unlocks all doors. - Locks all doors. - Turns on the interior lamps after either front door handle is lifted. - Turns on the interior lamps when using a keyless entry remote transmitter. - Activates and deactivates a personal security panic alarm feature that sounds the horn and flashes the parking lamps and headlamps. - Activates the lock verify feature that sounds the horn when the lock button is pressed on the keyless entry remote transmitter twice within five seconds. - Remembers to lock the sliding door if the door locks are activated when the sliding door is open. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Programming Procedure Keyless Entry Module: Service and Repair Programming Procedure Programming - Keyless Entry Remote Transmitter NOTE: To program (or reprogram) a keyless entry remote transmitter into the Remote Keyless Entry (RKE) module, perform the following steps: 1. Turn the key to the RUN or ACC position and short the two terminals of the program connector, a two-pin connector located at the base of the steering column connected to the ignition switch wiring harness. All doors should lock and then unlock. 2. Press any button on each keyless entry remote transmitter in turn. All doors should lock and then unlock. If the door locks do not respond, press the button again (up to three times maximum with the same keyless entry remote transmitter). 3. Repeat Step 2 to program additional keyless entry remote transmitters into the RKE module (up to four keyless entry remote transmitters maximum). 4. Turn the key off. 5. Remove the short from the program connector. All doors should lock and then unlock. 6. Verify that the keyless entry remote transmitters have been successfully programmed by pressing the lock or unlock button on each one, and observing that the system responds by locking and unlocking the doors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Programming Procedure > Page 9345 Keyless Entry Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the body side trim finish panel. 1 Remove the three finish panel pushpins. 2 Remove the finish panel from the body side. 3. Remove the remote keyless entry module. 1 Disconnect the electrical connectors. 2 Remove the two nuts. 3 Remove the module. INSTALLATION 1. To install, reverse the removal procedure. - If installing a new module it is necessary to reprogram Remote Keyless Entry Transmitters. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Programming Connector > Component Information > Locations Keyless Entry Programming Connector: Locations A two-pin connector located at the base of the steering column connected to the ignition switch wiring harness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Transmitter: Customer Interest Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9357 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9358 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9364 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9365 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 9366 Keyless Entry Transmitter: Description and Operation The electronic door lock control system is supplied with two, three-button, hand-held keyless entry remote transmitters. The keyless entry remote transmitters have three different shaped buttons, with icons used to identify the lock, unlock and panic features. NOTE: The electronic door lock control features will not function when the key is in run or accessory. To unlock the driver front door, press the unlock button once on a keyless entry remote transmitter that has been programmed into the RKE module. To unlock all doors, press the unlock button on a keyless entry remote transmitter twice. The second press must be within five seconds of the first. If more than five seconds have elapsed since the first press of the unlock button, pressing the unlock button again will only unlock the driver front door. To turn on the interior lamps, press the unlock button. To lock all doors, press the lock button on a keyless entry remote transmitter once. If the sliding door was open during the lock operation, the memory lock feature will activate to lock the sliding door after it is closed again. Pressing the lock button a second time within five seconds will lock the locks again and activate the lock verify feature which will provide a chirp" from the horn. To activate the personal security alarm, press the panic button on a transmitter. The horn will sound and the parking lamps and headlamps will flash for a Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 9367 maximum of three minutes. Activating the panic alarm also illuminates the interior lamps. To deactivate the personal security alarm, press the panic button on the same keyless entry remote transmitter that was used to activate the alarm, or turn the key on. The RKE module will erase all previous keyless entry remote transmitters from memory when the keyless entry remote transmitters are programmed or reprogrammed. NOTE: The RKE module can store up to four keyless entry remote transmitters in memory. When troubleshooting the electronic door lock control system, it is essential that the customer leaves at least one keyless entry remote transmitter with the vehicle. If the customer has purchased additional keyless entry remote transmitters, lost one, or if one must be reprogrammed into the RKE module, all keyless entry remote transmitters must be available for reprogramming at the same time. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 9368 Keyless Entry Transmitter: Service and Repair Programming - Keyless Entry Remote Transmitter NOTE: To program (or reprogram) a keyless entry remote transmitter into the Remote Keyless Entry (RKE) module, perform the following steps: 1. Turn the key to the RUN or ACC position and short the two terminals of the program connector, a two-pin connector located at the base of the steering column connected to the ignition switch wiring harness. All doors should lock and then unlock. 2. Press any button on each keyless entry remote transmitter in turn. All doors should lock and then unlock. If the door locks do not respond, press the button again (up to three times maximum with the same keyless entry remote transmitter). 3. Repeat Step 2 to program additional keyless entry remote transmitters into the RKE module (up to four keyless entry remote transmitters maximum). 4. Turn the key off. 5. Remove the short from the program connector. All doors should lock and then unlock. 6. Verify that the keyless entry remote transmitters have been successfully programmed by pressing the lock or unlock button on each one, and observing that the system responds by locking and unlocking the doors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair Power Door Lock Actuator: Service and Repair REMOVAL 1. Remove the door panel and watershield. 2. Remove the door latch on hinged doors or latch remote control on a sliding door. 3. Drill out the rivet, and remove the actuator. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Full Body Views The Memory Lock Module is located behind LH "B" pillar. NOTE: Systems without memory lock option do not use a door lock relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 9376 Memory Lock Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch Master Window/Door Lock Control Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 9381 Rear Power Door Lock Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 9382 RH Power Door Lock/Window Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9387 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9388 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9389 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9390 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9391 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Power Mirror Switch (Without Door Trim) (C508) Power Mirror Switch (Without Door Trim) (C505) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 9396 Power Mirror Switch: Service and Repair REMOVAL 1. Pry the plate assembly upward. 2. Disconnect the electrical connector and remove the switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9406 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9407 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9408 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9409 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9410 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9416 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9417 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9418 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9419 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9420 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs Paint: All Technical Service Bulletins Paint - Materials For After Warranty/Warranty Repairs Article No. 98-18-2 09/14/98 PAINT - EXTERIOR - WORLDWIDE RECOMMENDED PAINT MATERIALS FOR WARRANTY AND AFTER WARRANTY REPAIRS FORD: 1997 ASPIRE, PROBE, THUNDERBIRD 1997-98 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1997 COUGAR 1997-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR 1997-98 ECONOLINE, EXPEDITION, EXPLORER, F SUPER DUTY, F-150-350 SERIES, F-47, MOUNTAINEER, RANGER, VILLAGER, WINDSTAR 1998 NAVIGATOR MEDIUM/HEAVY TRUCK: 1997-98 AEROMAX, CARGO SERIES, F & B SERIES, L SERIES, LOUISVILLE This TSB article is being republished in its entirety to add additional paint information. ISSUE Ford Motor Company's goal is to eliminate paint related repeat repairs and increase customer satisfaction. To meet this goal, Ford has tested refinish paint materials that are used for warranty. Tests conducted were designed around OEM Refinish Material Reliability and Durability Standards. ACTION Ford Customer Service Division (FCSD) has released a paint material specification (WSS-M2P100-D) to the major worldwide paint supply companies for testing refinish paint systems. These paint systems are used for refinishing service parts as well as repair steel and plastic OEM finishes. SYSTEMS TESTED Ford Motor Company has completed testing of refinish paint materials that are compliant to U.S. "National Rule," "Canadian Rule" and European VOC (Volatile Organic Compounds) regulations. NOTE TESTING OF CALIFORNIA VOC COMPLIANT SYSTEMS WILL BEGIN 9/98 DUE TO A RECENT MORATORIUM REQUIRING NEW EMISSION COMPLIANT PRODUCTS. SELECTION AND PREPARATION Each paint manufacturer was asked to submit worldwide "in-use" paint systems for testing. The paint materials used for testing were obtained by Ford from local paint jobbers and distributors and/or shipped in from Europe. Employees of each paint company prepared and sprayed the test panels. All testing was completed at the Ford Central Laboratory facility. SUBSTRATES AND TESTS The paint materials approved from these specifications were tested over the following substrates: cold rolled steel, E-coated steel, bare galvanized steel, sanded OEM finish, and TPO plastic. A select group of tests including salt spray, initial adhesion, chipping, fuel resistance, and thermal shock were used for screening. As the companies passed the screening tests, they were required to complete the balance of the tests listed in the specifications. Each panel was tested and reviewed per OEM testing methods. PAINT PRODUCT CHANGES If a paint company decides to introduce a new product into a tested system (i.e., new primer, same clearcoat), the entire system will require retesting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9425 Systems will only be tested once a year. Cost of testing will be the responsibility of the paint suppliers. APPROVED SUPPLIERS AND MATERIALS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9426 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9427 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9428 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9429 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9430 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9431 The Charts following this article (Figures 1-7) indicate paint suppliers and materials. Dealers should begin to use the recommended paint materials as soon as practical. Dealers without a body shop should provide a copy of this bulletin to the independent body shop performing their warranty repairs. The products listed in this bulletin may be made mandatory sometime in the future. As a result, dealers that have jobber/paint company contractual agreements should only contract with recommended suppliers (when existing contracts expire) CONCLUSIONS Testing of refinish materials will raise standards for these materials. These improved standards will result in improved customer satisfaction. OTHER APPLICABLE ARTICLES: NONE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9432 SUPERSEDES: 98-9-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-4-4 > Mar > 98 > Paint - Anti Chip Stone Abrasion Undercoat Service Tip Paint: All Technical Service Bulletins Paint - Anti Chip Stone Abrasion Undercoat Service Tip Article No. 98-4-4 03/02/98 PAINT - ANTI-CHIP STONE ABRASION UNDERCOAT - SERVICE TIP FORD: 1998 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1998 CONTINENTAL, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR 1998 ECONOLINE, EXPEDITION, EXPLORER, F SUPER DUTY, F-150, F-250 LD, MOUNTAINEER, NAVIGATOR, RANGER, VILLAGER, WINDSTAR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1998 F & B SERIES ISSUE: There may be some difficulty in matching the texture of the OEM Anti-chip Stone Abrasion material to repair materials when servicing. ACTION: Remove the affected material, apply repair material, and paint. Refer to the following Service Procedure for details. WARNING: WEAR RESPIRATORY PROTECTION. WEAR PROTECTIVE CLOTHING WHEN EVER POTENTIALLY HAZARDOUS MATERIALS OR CONDITIONS EXIST IN THE SHOP. Areas that have been treated with Anti-chip Stone Abrasion materials show more textured appearance than the other painted areas of the body. Areas of application are the rocker panels and areas fore and aft of the rear wheels. Ford uses two types of stone abrasion materials, urethane (orange peel appearance) and PVC (smooth appearance). When repairs are needed, the coating must be removed from the entire side of the vehicle. No spot repairs can be performed on this material. NOTE: THIS PROCEDURE HIGHLIGHTS BASF STONE ABRASION MATERIAL; HOWEVER, OTHER MATERIALS LISTED BELOW MAY BE USED. ANY FORD APPROVED PAINT SYSTEM CAN BE USED. SERVICE PROCEDURE 1. Thoroughly wash the vehicle with soap and warm water. Power wash any heavy deposits of grime. 2. Remove all traces of grease, wax, and oil with Glasurit 541-5 Silicone and Tar Remover. 3. Sand previously painted areas with 240/P320 grit sand paper. 4. Wipe the area clean with a pre-paint cleaner, then wipe with tack cloth. NOTE: ALL BODY FILLER MUST BE PRIMED BEFORE STONE ABRASION MATERIAL IS APPLIED. FOLLOW RECOMMENDED FLASH TIME FOR PRIMER MATERIALS. 5. Mix and spray one (1) full wet coat of epoxy primer. NOTE: THE AMOUNT OF TEXTURE IS HIGHLY DEPENDENT ON APPLICATION TECHNIQUE AND SPRAY EQUIPMENT. USE A GRAVITY FEED GUN WITH 2.2 mm TIP SIZE. FOLLOW RECOMMENDED FLASH TIME. ALLOW MATERIAL TO DRY BEFORE TOPCOATING. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-4-4 > Mar > 98 > Paint - Anti Chip Stone Abrasion Undercoat Service Tip > Page 9437 BAKE TIME 30 MINUTES AT 60°C (140°F) OR INFRA-RED LIGHT 7-20 MINUTES. AIR DRY 2 HOURS. REMOVE ANY OVERSPRAY WITHIN 15 MINUTES WITH A DAMP SPONGE (WATER) OR WIPE WITH 352-91 REDUCER. CLEAN SPRAY EQUIPMENT IMMEDIATELY WITH WATER. 6. Spray one (1) or two (2) full wet coat(s) of ready-to-spray Anti-chip Stone Abrasion material. 7. Mix and spray Ford approved basecoat material to hiding. Follow recommended flash time. 8. Mix and spray two (2) full wet coats of Ford approved clearcoat material. Follow recommended flash time. Anti-chip Stone Abrasion Materials: ^ Glasurit 1109-1240-6 Stone Chip Protector ^ Gravi-tex ^ Dominion Shure Seal Gravel Gard III ^ Dominion Shure Seal Rocker Gard 8949 ^ 3M Rocker Schutz ^ 3M Rocker Gard II ^ PPG RoadGard DX54 ^ Spies Hecker Stone Chip Protector 7100-7104 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-3-3 > Feb > 98 > Paint - Surface Defect Removal Without Repainting Technical Service Bulletin # 98-3-3 Date: 980216 Paint - Surface Defect Removal Without Repainting Article No. 98-3-3 02/16/98 PAINT - SURFACE DEFECT REMOVAL WITHOUT REPAINTING - SERVICE TIP FORD: 1997 ASPIRE, PROBE, THUNDERBIRD 1997-98 CONTOUR 1998 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1997 COUGAR 1997-98 MYSTIQUE 1998 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR 1997-98 EXPEDITION, EXPLORER, F-150, F-250 LD, F-250 LD, MOUNTAINEER, RANGER, VILLAGER, WINDSTAR 1998 ECONOLINE, NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1997 AEROMAX, CARGO SERIES, F & B SERIES, L SERIES, LOUISVILLE ISSUE: Exterior paint surface maintenance or damage repair where the basecoat does not show through should be restored without repainting. The restoration of gloss and luster may be enhanced with new techniques and three new Ford approved materials. ACTION: The following procedure is applicable to repair surface conditions such as dirt particles, "orange peel," runs, sags, industrial fallout stains, swirl marks, and scratches. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Preparation The affected surface must be clean and dry to be repaired. Mask off adjacent panels, mouldings, stripe, and character lines as required. CAUTION: EYE PROTECTION SHOULD BE WORN. JEWELRY, WATCHES, AND BELT BUCKLES MUST BE REMOVED OR COVERED TO PREVENT ACCIDENTAL DAMAGE TO PAINT FINISH. NOTE: CHECK PAINT FILM THICKNESS BEFORE AND AFTER PERFORMANCE OF REPAIRS. MAXIMUM PAINT FILM REMOVAL IS 0.3 OF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-3-3 > Feb > 98 > Paint - Surface Defect Removal Without Repainting > Page 9442 A MIL. NOTE: PERFORM A TRIAL REPAIR ON A SMALL AREA. FIRST, TRY A POLISH; IF THIS IS NOT SUCCESSFUL, TRY BUFFING WITH FORD MEDIUM DUTY BODY SHOP PAINT CLEANER (F6AZ-19530-BA) OR FORD HEAVY DUTY BODY SHOP PAINT CLEANER (F6AZ-19530-CA) AND, FINALLY, USE WET SANDING TO REMOVE THE CONDITION. USE THE MOST EFFECTIVE TECHNIQUE ON THE REMAINING AREAS. AN OUTLINE OF THE COMPLETE PROCEDURE AND REQUIRED MATERIALS FOLLOWS. Service Notes 1. Remove sanding marks with Ford Medium or Heavy Duty Body Shop Paint Cleaner. 2. Swirl marks, evident after buffing, may be removed by polishing with Ford Light Duty Body Shop Polish (F6AZ-19530-BA). 3. Remove light scratches and small dirt particles with a power buffer and Ford Medium Duty Body Shop Pain Cleaner followed by polishing with Ford Light Duty Body Shop Polish. 4. Remove deep scratches and heavy dirt particles or "orange peel" by wet sanding. Removing Scratches/Swirl Marks/Restore Dull Finish The Black and Decker Buffmaster(R) 5950 is the tool of choice. Variable speed buffers are available in a variety of buffing speeds. The recommended speed range is (1200-1750 rpm). 1. Apply a small amount of Ford Light Duty Body Shop Polish to the pad. ^ Always keep the face of the buffing pad completely flat to the surface, reducing the risk of buffer swirl marks. Watch your pad, especially on angled surfaces, to be certain that it stays flat ^ When "buffing out" oxidation or other paint defects with a cleaning material, use a liberal amount of material, slower buffing motion and added downward pressure to increase cutting action 2. When polishing, keep the pad flat against the surface. Do not bear down. The weight of the buffer is suffi6ient. CAUTION: DO NOT MIX PRODUCTS. USE A SEPARATE, DEDICATED BUFFING PAD FOR EACH PRODUCT TO ACHIEVE DESIRED RESULTS. Med. Scratches, Small Dirt Particles, Grind & Sanding Marks 1. Apply Ford Medium Duty Body Shop Paint Cleaner to the panel with a clean compound pad on the wheel. 2. Spread the product evenly and continue buffing until the condition is removed. 3. Keep the wheel flat to the surface and use light to moderate pressure and long strokes. 4. Periodically check the finish and add product as required. 5. When buffing is complete, polish the panel as described previously. Untreated wool cutting pads are the most effective cutting pads to use with Ford Heavy Duty Body Shop Paint Cleaner for removing paint defects and heavy oxidation. Following the use of a wool cutting pad, it may be necessary to polish the finish with a foam pad to remove the deep swirl marks. NOTE: ALWAYS KEEP THE PAD MOVING AND LIMIT YOUR STROKES OVER THE BLEMISH TO PREVENT EXCESSIVE HEAT BUILDUP AND POSSIBLE BURN-THROUGH. STOP IMMEDIATELY IF THE SURFACE BECOMES TOO HOT TO LAY THE PALM OF YOUR HAND ON IT. KEEP SURFACE TEMPERATURE BELOW 38°C (100°F). NOTE: HEAT BUILDUP: WHEN BUFFING CREATES EXCESSIVE HEAT, HAZING MAY APPEAR ACROSS THE SURFACE BEING BUFFED AND THE PRODUCT MAY DRY LIKE A FILM AND REFUSE TO BUFF OUT. TO REMEDY, WIPE THE AREA DOWN WITH COOL WATER, DRY THE SURFACE AND RESUME BUFFING, AT A LOWER RPM IF POSSIBLE. NOTE: STATIC: STATIC ELECTRICITY MAY BE PRESENT ON A PAINTED FIBERGLASS/PLASTIC SURFACE BEING BUFFED. THE MATERIAL MAY DRY LIKE A FILM OR TURN "GUMMY" AND BEGIN TO BALL UP. TO REMEDY, ATTACH A GROUNDING CLAMP TO THE SURFACE BEING BUFFED TO ELIMINATE THE STATIC CHARGE. Run and Sag Removal This procedure consists of shaving the run(s) or sag(s) flush with a commercial single edge razor blade, shaving file or sanding. NOTE: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-3-3 > Feb > 98 > Paint - Surface Defect Removal Without Repainting > Page 9443 IF IT IS NECESSARY TO SHAVE RUNS AND SAGS WITH A RAZOR BLADE, FIRST DULL THE CORNERS WITH SANDPAPER TO AVOID SCRATCHING THE ADJACENT AREA FINISH. 1. Lightly scrape the defect until the defect is level with the surface. 2. Wet sand or compound the surface to remove any small scratches. 3. Polish to complete the repair. Wet Sanding For Defect Removal ^ Typical paint defects that are repaired with this system include: dirt in paint, solvent "pop," cratering, "orange peel," drips, scratches, water spots, and acid rain ^ Always use the least abrasive (highest grit) sanding products possible to do this job The following wet sanding procedure utilizes light grit sandpaper or sanding blocks for removal of surface damage. These materials cut quickly, leaving a uniform finish requiring a minimum of buffing to restore gloss. 1. Mist or apply water on the area to be sanded. Continue to flush water on the surface during sanding for maximum lubrication. 2. Use sanding blocks or paper. Keep abrasion to the immediate area of the defect. Keep blocks in water when not in use. 3. If the cutting is too slow, switch to a lower grade block or paper and resume sanding. When 90% of the defect is removed, switch to a 2000 grade sand paper or sanding block to finish smoothing and prepare the surface for buffing. 4. Sanding blocks can be shaped to work on any angle. When the block is wet, rub it against a dry sanding block for shaping. 5. When using sanding papers, wrap the paper tightly around a backing pad. This pad evenly distributes pressure over the entire surface of the sanding paper. This creates a uniform sanding pattern. 6. Plan your strokes to limit the abrasion to the smallest area possible. 7. Always finish sanding with 2000 Grit Sanding Paper. 2000 grit paper will reduce the need for heavy compound, however, the area should be finished by using a cleaner that will remove the sanding scratches left by these papers. NOTE: IF MULTIPLE GRIT PAPERS ARE USED, IT IS A GOOD IDEA TO CHANGE THE DIRECTION OF SANDING STROKE TO ALLOW YOU TO SEE THAT THE PREVIOUS GRIT SCRATCH IS REMOVED. 8. Buff out sanding marks by applying Ford Medium Duty Body Shop Paint Cleaner with a "Foam" Cutting Pad (W7000). Follow with Ford Light Duty Body Shop Polish for a swirl-free gloss. General Techniques and Hints ^ "Foam" buffing pads yield maximum gloss and depth of color on all types of paint finishes without creating buffer swirl marks ^ Always apply product directly to pad, not to oxidized paint surface. Dry paint absorbs material into pores upon contact ^ Avoid short rapid strokes. Move the buffer slowly across the surface using long straight motions and overlap by 50% the buffing pattern left by the previous pass. This insures uniform coverage and allows both material and buffer to perform at maximum efficiency ^ Avoid buffing directly on raised character lines. The reduced paint film on these surfaces increases the risk of paint burn-through. It is best to buff up to them from each side ^ If a paint blemish remains after buffing, reapply a small amount of material over the blemish~ Confine your buffing strokes to the immediate area of the blemish while applying additional downward pressure and keeping the pad flat Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs Paint: All Technical Service Bulletins Paint - Materials For After Warranty/Warranty Repairs Article No. 98-18-2 09/14/98 PAINT - EXTERIOR - WORLDWIDE RECOMMENDED PAINT MATERIALS FOR WARRANTY AND AFTER WARRANTY REPAIRS FORD: 1997 ASPIRE, PROBE, THUNDERBIRD 1997-98 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1997 COUGAR 1997-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR 1997-98 ECONOLINE, EXPEDITION, EXPLORER, F SUPER DUTY, F-150-350 SERIES, F-47, MOUNTAINEER, RANGER, VILLAGER, WINDSTAR 1998 NAVIGATOR MEDIUM/HEAVY TRUCK: 1997-98 AEROMAX, CARGO SERIES, F & B SERIES, L SERIES, LOUISVILLE This TSB article is being republished in its entirety to add additional paint information. ISSUE Ford Motor Company's goal is to eliminate paint related repeat repairs and increase customer satisfaction. To meet this goal, Ford has tested refinish paint materials that are used for warranty. Tests conducted were designed around OEM Refinish Material Reliability and Durability Standards. ACTION Ford Customer Service Division (FCSD) has released a paint material specification (WSS-M2P100-D) to the major worldwide paint supply companies for testing refinish paint systems. These paint systems are used for refinishing service parts as well as repair steel and plastic OEM finishes. SYSTEMS TESTED Ford Motor Company has completed testing of refinish paint materials that are compliant to U.S. "National Rule," "Canadian Rule" and European VOC (Volatile Organic Compounds) regulations. NOTE TESTING OF CALIFORNIA VOC COMPLIANT SYSTEMS WILL BEGIN 9/98 DUE TO A RECENT MORATORIUM REQUIRING NEW EMISSION COMPLIANT PRODUCTS. SELECTION AND PREPARATION Each paint manufacturer was asked to submit worldwide "in-use" paint systems for testing. The paint materials used for testing were obtained by Ford from local paint jobbers and distributors and/or shipped in from Europe. Employees of each paint company prepared and sprayed the test panels. All testing was completed at the Ford Central Laboratory facility. SUBSTRATES AND TESTS The paint materials approved from these specifications were tested over the following substrates: cold rolled steel, E-coated steel, bare galvanized steel, sanded OEM finish, and TPO plastic. A select group of tests including salt spray, initial adhesion, chipping, fuel resistance, and thermal shock were used for screening. As the companies passed the screening tests, they were required to complete the balance of the tests listed in the specifications. Each panel was tested and reviewed per OEM testing methods. PAINT PRODUCT CHANGES If a paint company decides to introduce a new product into a tested system (i.e., new primer, same clearcoat), the entire system will require retesting. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9449 Systems will only be tested once a year. Cost of testing will be the responsibility of the paint suppliers. APPROVED SUPPLIERS AND MATERIALS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9450 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9451 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9452 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9453 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9454 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9455 The Charts following this article (Figures 1-7) indicate paint suppliers and materials. Dealers should begin to use the recommended paint materials as soon as practical. Dealers without a body shop should provide a copy of this bulletin to the independent body shop performing their warranty repairs. The products listed in this bulletin may be made mandatory sometime in the future. As a result, dealers that have jobber/paint company contractual agreements should only contract with recommended suppliers (when existing contracts expire) CONCLUSIONS Testing of refinish materials will raise standards for these materials. These improved standards will result in improved customer satisfaction. OTHER APPLICABLE ARTICLES: NONE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 9456 SUPERSEDES: 98-9-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-4-4 > Mar > 98 > Paint - Anti Chip Stone Abrasion Undercoat Service Tip Paint: All Technical Service Bulletins Paint - Anti Chip Stone Abrasion Undercoat Service Tip Article No. 98-4-4 03/02/98 PAINT - ANTI-CHIP STONE ABRASION UNDERCOAT - SERVICE TIP FORD: 1998 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1998 CONTINENTAL, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR 1998 ECONOLINE, EXPEDITION, EXPLORER, F SUPER DUTY, F-150, F-250 LD, MOUNTAINEER, NAVIGATOR, RANGER, VILLAGER, WINDSTAR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1998 F & B SERIES ISSUE: There may be some difficulty in matching the texture of the OEM Anti-chip Stone Abrasion material to repair materials when servicing. ACTION: Remove the affected material, apply repair material, and paint. Refer to the following Service Procedure for details. WARNING: WEAR RESPIRATORY PROTECTION. WEAR PROTECTIVE CLOTHING WHEN EVER POTENTIALLY HAZARDOUS MATERIALS OR CONDITIONS EXIST IN THE SHOP. Areas that have been treated with Anti-chip Stone Abrasion materials show more textured appearance than the other painted areas of the body. Areas of application are the rocker panels and areas fore and aft of the rear wheels. Ford uses two types of stone abrasion materials, urethane (orange peel appearance) and PVC (smooth appearance). When repairs are needed, the coating must be removed from the entire side of the vehicle. No spot repairs can be performed on this material. NOTE: THIS PROCEDURE HIGHLIGHTS BASF STONE ABRASION MATERIAL; HOWEVER, OTHER MATERIALS LISTED BELOW MAY BE USED. ANY FORD APPROVED PAINT SYSTEM CAN BE USED. SERVICE PROCEDURE 1. Thoroughly wash the vehicle with soap and warm water. Power wash any heavy deposits of grime. 2. Remove all traces of grease, wax, and oil with Glasurit 541-5 Silicone and Tar Remover. 3. Sand previously painted areas with 240/P320 grit sand paper. 4. Wipe the area clean with a pre-paint cleaner, then wipe with tack cloth. NOTE: ALL BODY FILLER MUST BE PRIMED BEFORE STONE ABRASION MATERIAL IS APPLIED. FOLLOW RECOMMENDED FLASH TIME FOR PRIMER MATERIALS. 5. Mix and spray one (1) full wet coat of epoxy primer. NOTE: THE AMOUNT OF TEXTURE IS HIGHLY DEPENDENT ON APPLICATION TECHNIQUE AND SPRAY EQUIPMENT. USE A GRAVITY FEED GUN WITH 2.2 mm TIP SIZE. FOLLOW RECOMMENDED FLASH TIME. ALLOW MATERIAL TO DRY BEFORE TOPCOATING. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-4-4 > Mar > 98 > Paint - Anti Chip Stone Abrasion Undercoat Service Tip > Page 9461 BAKE TIME 30 MINUTES AT 60°C (140°F) OR INFRA-RED LIGHT 7-20 MINUTES. AIR DRY 2 HOURS. REMOVE ANY OVERSPRAY WITHIN 15 MINUTES WITH A DAMP SPONGE (WATER) OR WIPE WITH 352-91 REDUCER. CLEAN SPRAY EQUIPMENT IMMEDIATELY WITH WATER. 6. Spray one (1) or two (2) full wet coat(s) of ready-to-spray Anti-chip Stone Abrasion material. 7. Mix and spray Ford approved basecoat material to hiding. Follow recommended flash time. 8. Mix and spray two (2) full wet coats of Ford approved clearcoat material. Follow recommended flash time. Anti-chip Stone Abrasion Materials: ^ Glasurit 1109-1240-6 Stone Chip Protector ^ Gravi-tex ^ Dominion Shure Seal Gravel Gard III ^ Dominion Shure Seal Rocker Gard 8949 ^ 3M Rocker Schutz ^ 3M Rocker Gard II ^ PPG RoadGard DX54 ^ Spies Hecker Stone Chip Protector 7100-7104 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-3-3 > Feb > 98 > Paint - Surface Defect Removal Without Repainting Technical Service Bulletin # 98-3-3 Date: 980216 Paint - Surface Defect Removal Without Repainting Article No. 98-3-3 02/16/98 PAINT - SURFACE DEFECT REMOVAL WITHOUT REPAINTING - SERVICE TIP FORD: 1997 ASPIRE, PROBE, THUNDERBIRD 1997-98 CONTOUR 1998 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1997 COUGAR 1997-98 MYSTIQUE 1998 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR 1997-98 EXPEDITION, EXPLORER, F-150, F-250 LD, F-250 LD, MOUNTAINEER, RANGER, VILLAGER, WINDSTAR 1998 ECONOLINE, NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1997 AEROMAX, CARGO SERIES, F & B SERIES, L SERIES, LOUISVILLE ISSUE: Exterior paint surface maintenance or damage repair where the basecoat does not show through should be restored without repainting. The restoration of gloss and luster may be enhanced with new techniques and three new Ford approved materials. ACTION: The following procedure is applicable to repair surface conditions such as dirt particles, "orange peel," runs, sags, industrial fallout stains, swirl marks, and scratches. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Preparation The affected surface must be clean and dry to be repaired. Mask off adjacent panels, mouldings, stripe, and character lines as required. CAUTION: EYE PROTECTION SHOULD BE WORN. JEWELRY, WATCHES, AND BELT BUCKLES MUST BE REMOVED OR COVERED TO PREVENT ACCIDENTAL DAMAGE TO PAINT FINISH. NOTE: CHECK PAINT FILM THICKNESS BEFORE AND AFTER PERFORMANCE OF REPAIRS. MAXIMUM PAINT FILM REMOVAL IS 0.3 OF Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-3-3 > Feb > 98 > Paint - Surface Defect Removal Without Repainting > Page 9466 A MIL. NOTE: PERFORM A TRIAL REPAIR ON A SMALL AREA. FIRST, TRY A POLISH; IF THIS IS NOT SUCCESSFUL, TRY BUFFING WITH FORD MEDIUM DUTY BODY SHOP PAINT CLEANER (F6AZ-19530-BA) OR FORD HEAVY DUTY BODY SHOP PAINT CLEANER (F6AZ-19530-CA) AND, FINALLY, USE WET SANDING TO REMOVE THE CONDITION. USE THE MOST EFFECTIVE TECHNIQUE ON THE REMAINING AREAS. AN OUTLINE OF THE COMPLETE PROCEDURE AND REQUIRED MATERIALS FOLLOWS. Service Notes 1. Remove sanding marks with Ford Medium or Heavy Duty Body Shop Paint Cleaner. 2. Swirl marks, evident after buffing, may be removed by polishing with Ford Light Duty Body Shop Polish (F6AZ-19530-BA). 3. Remove light scratches and small dirt particles with a power buffer and Ford Medium Duty Body Shop Pain Cleaner followed by polishing with Ford Light Duty Body Shop Polish. 4. Remove deep scratches and heavy dirt particles or "orange peel" by wet sanding. Removing Scratches/Swirl Marks/Restore Dull Finish The Black and Decker Buffmaster(R) 5950 is the tool of choice. Variable speed buffers are available in a variety of buffing speeds. The recommended speed range is (1200-1750 rpm). 1. Apply a small amount of Ford Light Duty Body Shop Polish to the pad. ^ Always keep the face of the buffing pad completely flat to the surface, reducing the risk of buffer swirl marks. Watch your pad, especially on angled surfaces, to be certain that it stays flat ^ When "buffing out" oxidation or other paint defects with a cleaning material, use a liberal amount of material, slower buffing motion and added downward pressure to increase cutting action 2. When polishing, keep the pad flat against the surface. Do not bear down. The weight of the buffer is suffi6ient. CAUTION: DO NOT MIX PRODUCTS. USE A SEPARATE, DEDICATED BUFFING PAD FOR EACH PRODUCT TO ACHIEVE DESIRED RESULTS. Med. Scratches, Small Dirt Particles, Grind & Sanding Marks 1. Apply Ford Medium Duty Body Shop Paint Cleaner to the panel with a clean compound pad on the wheel. 2. Spread the product evenly and continue buffing until the condition is removed. 3. Keep the wheel flat to the surface and use light to moderate pressure and long strokes. 4. Periodically check the finish and add product as required. 5. When buffing is complete, polish the panel as described previously. Untreated wool cutting pads are the most effective cutting pads to use with Ford Heavy Duty Body Shop Paint Cleaner for removing paint defects and heavy oxidation. Following the use of a wool cutting pad, it may be necessary to polish the finish with a foam pad to remove the deep swirl marks. NOTE: ALWAYS KEEP THE PAD MOVING AND LIMIT YOUR STROKES OVER THE BLEMISH TO PREVENT EXCESSIVE HEAT BUILDUP AND POSSIBLE BURN-THROUGH. STOP IMMEDIATELY IF THE SURFACE BECOMES TOO HOT TO LAY THE PALM OF YOUR HAND ON IT. KEEP SURFACE TEMPERATURE BELOW 38°C (100°F). NOTE: HEAT BUILDUP: WHEN BUFFING CREATES EXCESSIVE HEAT, HAZING MAY APPEAR ACROSS THE SURFACE BEING BUFFED AND THE PRODUCT MAY DRY LIKE A FILM AND REFUSE TO BUFF OUT. TO REMEDY, WIPE THE AREA DOWN WITH COOL WATER, DRY THE SURFACE AND RESUME BUFFING, AT A LOWER RPM IF POSSIBLE. NOTE: STATIC: STATIC ELECTRICITY MAY BE PRESENT ON A PAINTED FIBERGLASS/PLASTIC SURFACE BEING BUFFED. THE MATERIAL MAY DRY LIKE A FILM OR TURN "GUMMY" AND BEGIN TO BALL UP. TO REMEDY, ATTACH A GROUNDING CLAMP TO THE SURFACE BEING BUFFED TO ELIMINATE THE STATIC CHARGE. Run and Sag Removal This procedure consists of shaving the run(s) or sag(s) flush with a commercial single edge razor blade, shaving file or sanding. NOTE: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-3-3 > Feb > 98 > Paint - Surface Defect Removal Without Repainting > Page 9467 IF IT IS NECESSARY TO SHAVE RUNS AND SAGS WITH A RAZOR BLADE, FIRST DULL THE CORNERS WITH SANDPAPER TO AVOID SCRATCHING THE ADJACENT AREA FINISH. 1. Lightly scrape the defect until the defect is level with the surface. 2. Wet sand or compound the surface to remove any small scratches. 3. Polish to complete the repair. Wet Sanding For Defect Removal ^ Typical paint defects that are repaired with this system include: dirt in paint, solvent "pop," cratering, "orange peel," drips, scratches, water spots, and acid rain ^ Always use the least abrasive (highest grit) sanding products possible to do this job The following wet sanding procedure utilizes light grit sandpaper or sanding blocks for removal of surface damage. These materials cut quickly, leaving a uniform finish requiring a minimum of buffing to restore gloss. 1. Mist or apply water on the area to be sanded. Continue to flush water on the surface during sanding for maximum lubrication. 2. Use sanding blocks or paper. Keep abrasion to the immediate area of the defect. Keep blocks in water when not in use. 3. If the cutting is too slow, switch to a lower grade block or paper and resume sanding. When 90% of the defect is removed, switch to a 2000 grade sand paper or sanding block to finish smoothing and prepare the surface for buffing. 4. Sanding blocks can be shaped to work on any angle. When the block is wet, rub it against a dry sanding block for shaping. 5. When using sanding papers, wrap the paper tightly around a backing pad. This pad evenly distributes pressure over the entire surface of the sanding paper. This creates a uniform sanding pattern. 6. Plan your strokes to limit the abrasion to the smallest area possible. 7. Always finish sanding with 2000 Grit Sanding Paper. 2000 grit paper will reduce the need for heavy compound, however, the area should be finished by using a cleaner that will remove the sanding scratches left by these papers. NOTE: IF MULTIPLE GRIT PAPERS ARE USED, IT IS A GOOD IDEA TO CHANGE THE DIRECTION OF SANDING STROKE TO ALLOW YOU TO SEE THAT THE PREVIOUS GRIT SCRATCH IS REMOVED. 8. Buff out sanding marks by applying Ford Medium Duty Body Shop Paint Cleaner with a "Foam" Cutting Pad (W7000). Follow with Ford Light Duty Body Shop Polish for a swirl-free gloss. General Techniques and Hints ^ "Foam" buffing pads yield maximum gloss and depth of color on all types of paint finishes without creating buffer swirl marks ^ Always apply product directly to pad, not to oxidized paint surface. Dry paint absorbs material into pores upon contact ^ Avoid short rapid strokes. Move the buffer slowly across the surface using long straight motions and overlap by 50% the buffing pattern left by the previous pass. This insures uniform coverage and allows both material and buffer to perform at maximum efficiency ^ Avoid buffing directly on raised character lines. The reduced paint film on these surfaces increases the risk of paint burn-through. It is best to buff up to them from each side ^ If a paint blemish remains after buffing, reapply a small amount of material over the blemish~ Confine your buffing strokes to the immediate area of the blemish while applying additional downward pressure and keeping the pad flat Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9468 Paint: By Symptom Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9469 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9470 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9471 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9472 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9473 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9474 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9475 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9476 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9477 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9478 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: Customer Interest Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9488 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9489 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation Keyless Entry Module: All Technical Service Bulletins Keyless Entry Transmitter - Intermittent Operation Article No. 99-23-11 11/15/99 REMOTE KEYLESS ENTRY (RKE) - TRANSMITTER HAS INTERMITTENT OPERATION OR LOW RANGE - VEHICLES BUILT THROUGH 2/28/1999 FORD: 1997-1999 ECONOLINE ISSUE Intermittent or low range of the Remote Keyless Entry (RKE) system may occur on some vehicles. This may be caused by the RKE module. ACTION Replace the RKE module and transmitters (Key Fobs, Type 2, Figure 2) with revised RKE module and transmitters (Key Fobs, Type 6, Figure 1). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9495 Refer to the following Service Procedure for details. NOTE INFORM CUSTOMER THAT THE REVISED RKE MODULE (XC2Z-15K602-AA) DOES NOT SUPPORT FRONT DOOR HANDLE-ACTUATED ILLUMINATED ENTRY OR VEHICLE LOCKED HEADLAMP VERIFICATION. THESE FEATURES ARE FOUND ON 1997, 1998 AND SOME 1999 ECONOLINE/E-SERIES WITH RKE. NOTE THE REVISED RKE MODULE WILL ONLY WORK WITH TYPE 6 TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. SERVICE PROCEDURE 1. Confirm the condition: a. Actuate the key fob at equal distances from each side of the vehicle. The system should react from all angles at a minimum radius of 9 meters (30 feet). System react test must be performed in an area absent of high powered electronics and clear from metal buildings and walls. b. If a condition of inconsistent/low range is confirmed, proceed with replacement of the RKE module and transmitters with the updated styles. 2. Remove/install RKE module: CAUTION ELECTRONIC MODULES ARE SENSITIVE TO ELECTRICAL CHARGES. IF EXPOSED TO THESE CHARGES, DAMAGE MAY RESULT. a. Disconnect the battery ground cable. Refer to the 1999 Econoline Workshop Manual, Section 414-01. b. Remove the left side, body side interior trim finish panel by removing the three (3) finish panel pushpins. The module is mounted to the body about 60 cm (2 feet) behind the driver's seat and about 60 cm (2 feet) above the floor. c. Remove the RKE module by disconnecting electrical connectors C335 and C336. d. Remove the two (2) mounting nuts and then remove the module. e. Install the revised RKE Module (XC2Z-15K602-AA) by reversing Steps 2a-2d. For further information on the removal and installation procedure, refer to the 1999 Econoline Workshop Manual, Section 419-10. 3. Program the RKE system: NOTE THE REMOTE KEYLESS ENTRY SYSTEM WITH A REVISED RKE MODULE (XC2Z-15K602-AA) INSTALLED IN AN ECONOLINE/E-SERIES BUILT THROUGH 2/28/1999, MAY BE PROGRAMMED WITH EITHER THE "EIGHT IGNITION SWITCH CYCLE" OR THE "TWO-PIN CONNECTOR SHORTED" METHODS. NOTE THE REVISED MODULE WILL ONLY WORK WITH TYPE 6 (F87Z-15K601-AB) TRANSMITTERS (ICON BUTTONS, FIGURE 1). ALL TRANSMITTERS WILL HAVE TO BE REPLACED IF UPDATING THE MODULE. Refer to the 1999 Econoline Workshop Manual, Page 501-14B-22, for RKE programming instructions after obtaining the correct number of Type 6 (F87Z-15K601-AB) transmitters. PART NUMBER PART NAME XC2Z-15K602-AA RKE Module F87Z-15K601-AB RKE Transmitter OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992311A Confirm RKE Inconsistent 0.5 Hr. Range And Replace RKE Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 99-23-11 > Nov > 99 > Keyless Entry Transmitter - Intermittent Operation > Page 9496 Module And Transmitters (Includes Time To Program Two Transmitters) DEALER CODING CONDITION BASIC PART NO. CODE 15k602 42 OASIS CODES: 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9497 Keyless Entry Module: Locations Full Body Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9498 The Remote Keyless Entry (RKE) module with integral receiver is located behind the B-pillar on the driver side. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9499 Keyless Entry Module: Diagrams Remote Keyless Entry Module (C335) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9500 Remote Keyless Entry Module (C336) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Page 9501 Keyless Entry Module: Description and Operation The Remote Keyless Entry (RKE) module performs the following functions: - Unlocks the driver front door. - Unlocks all doors. - Locks all doors. - Turns on the interior lamps after either front door handle is lifted. - Turns on the interior lamps when using a keyless entry remote transmitter. - Activates and deactivates a personal security panic alarm feature that sounds the horn and flashes the parking lamps and headlamps. - Activates the lock verify feature that sounds the horn when the lock button is pressed on the keyless entry remote transmitter twice within five seconds. - Remembers to lock the sliding door if the door locks are activated when the sliding door is open. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Programming Procedure Keyless Entry Module: Service and Repair Programming Procedure Programming - Keyless Entry Remote Transmitter NOTE: To program (or reprogram) a keyless entry remote transmitter into the Remote Keyless Entry (RKE) module, perform the following steps: 1. Turn the key to the RUN or ACC position and short the two terminals of the program connector, a two-pin connector located at the base of the steering column connected to the ignition switch wiring harness. All doors should lock and then unlock. 2. Press any button on each keyless entry remote transmitter in turn. All doors should lock and then unlock. If the door locks do not respond, press the button again (up to three times maximum with the same keyless entry remote transmitter). 3. Repeat Step 2 to program additional keyless entry remote transmitters into the RKE module (up to four keyless entry remote transmitters maximum). 4. Turn the key off. 5. Remove the short from the program connector. All doors should lock and then unlock. 6. Verify that the keyless entry remote transmitters have been successfully programmed by pressing the lock or unlock button on each one, and observing that the system responds by locking and unlocking the doors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Programming Procedure > Page 9504 Keyless Entry Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the body side trim finish panel. 1 Remove the three finish panel pushpins. 2 Remove the finish panel from the body side. 3. Remove the remote keyless entry module. 1 Disconnect the electrical connectors. 2 Remove the two nuts. 3 Remove the module. INSTALLATION 1. To install, reverse the removal procedure. - If installing a new module it is necessary to reprogram Remote Keyless Entry Transmitters. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Full Body Views The Memory Lock Module is located behind LH "B" pillar. NOTE: Systems without memory lock option do not use a door lock relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 9508 Memory Lock Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams Driver's Seat Motor Assembly Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: Customer Interest Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: All Technical Service Bulletins Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9526 Driver's Seat Regulator Control Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9527 Power Seat Switch: Service Precautions WARNING THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG-EQUIPPED VEHICLE AND WHEN HANDLING A BELT AND BUCKLE ASSEMBLY PRETENSIONER. - THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. NEVER PROBE THE CONNECTORS ON THE BELT AND BUCKLE ASSEMBLY PRE TENSIONER. DOING SO CAN RESULT IN BELT AND BUCKLE ASSEMBLY PRETENSIONER OR AIR BAG DEPLOYMENT AND CAN RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF SO EQUIPPED). NOTE: Be sure to disconnect auxiliary batteries and power supplies (if so equipped). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9528 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable(s). WARNING THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG-EQUIPPED VEHICLE AND WHEN HANDLING A BELT AND BUCKLE ASSEMBLY PRETENSIONER. - THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. NEVER PROBE THE CONNECTORS ON THE BELT AND BUCKLE ASSEMBLY PRE TENSIONER. DOING SO CAN RESULT IN BELT AND BUCKLE ASSEMBLY PRETENSIONER OR AIR BAG DEPLOYMENT AND CAN RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF SO EQUIPPED). NOTE: Be sure to disconnect auxiliary batteries and power supplies (if so equipped). 2. Remove the front seat from the vehicle. 1 Remove the plastic bolt covers. 2 Remove the nuts and bolts. 3 Disconnect the belt and buckle assembly pretensioner connector. 4 Remove the front seat NOTE: The front seat does not need to be removed in order to remove the seat control switch, but it may be easier to access the wiring connector and switch fasteners if the seat is removed. 3. Disconnect the power seat control switch connector. 4. Remove the appropriate seat back latch cover to access the switch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9529 5. Remove the power seat control switch. 1 Pull the front seat back latch lower cover away from the seat. 2 Pull the power seat control switch connector through the seat cushion. 3 Remove the screws. 4 Remove the power seat control switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Seat Leather - Cleaning Procedure Tips Seat Cover: Technical Service Bulletins Seat Leather - Cleaning Procedure Tips Article No. 98-17-1 09/01/98 SEAT - LEATHER CLEANING PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 THUNDERBIRD 1984-98 CROWN VICTORIA, ESCORT, MUSTANG 1986-98 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1984-94 TOPAZ 1984-97 COUGAR 1984-98 GRAND MARQUIS, TRACER 1984-99 TOWN CAR 1986-98 SABLE 1993-98 MARK VIII 1995-98 MYSTIQUE 1995-99 CONTINENTAL 1999 COUGAR LIGHT TRUCK: 1983-98 RANGER 1984-96 BRONCO 1984-97 F-250 HD 1984-98 ECONOLINE, F-150, F-250 LD 1986-97 AEROSTAR 1991-98 EXPLORER 1993-98 VILLAGER 1996-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to include the latest level parts and to include a revised Service Procedure. ISSUE The following TSB contains information regarding the cleaning of interior leather seats and trim. Improper cleaning procedures may damage the leather. If seats are not cleaned on a regular basis (every 4-6 weeks), normal wear and tear can cause excessive soiling. ACTION Ford Motor Company has developed a new kit (Deluxe Leather Care Kit - F8AZ-19G253-AA) to clean soiled seats without damaging the top coat of the leather. The kit contains a leather and vinyl cleaner along with a specially formulated sponge. Refer to the text for cleaning leather seats and trim. The Deluxe Leather Care Kit has been tested and approved for use on all Ford and Lincoln/Mercury leather and vinyl seating surfaces, and if used as directed, should be used for service repairs. Many household cleaners and sponges are too harsh to be used on leather and may actually cause permanent damage to the surface. Use this material on leather and vinyl seats that: ^ show excessive soiling ^ have been stained with coffee, lipstick, etc. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Seat Leather - Cleaning Procedure Tips > Page 9534 Refer to the instructions included in the kit for specific application procedures. After cleaning surface with cleaner and sponge, wipe area with water and a cotton cloth. NOTE AVOID EXCESSIVE APPLICATION OF CLEANER ALONG STITCHING. PART NUMBER PART NAME F8AZ-19G253-AA Deluxe Leather Care Kit OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 101000, 107000, 190000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair Seat Latch: Service and Repair REMOVAL 1. Remove the appropriate rear bench or bucket seat. NOTE The following procedure applies to both rear bucket and rear bench seats. - The removal procedure is similar for all of the rear seat back latch strikers. 2. Remove the bolts and washers retaining the rear seat back latch striker to the floorpan. - For the extended wagon fifth row bench seat, remove the retaining nuts (not shown). 3. Remove the rear seat back latch striker. INSTALLATION 1. Follow the removal procedure in reverse order. NOTE: Seal all bolt locations with a 0.19-mm (0.007-inch) bead of Caulking Cord D6AZ-19560-A or equivalent sealant meeting Ford specification ESB-M4G32-A. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch Master Window/Door Lock Control Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 9543 Rear Power Door Lock Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 9544 RH Power Door Lock/Window Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Power Mirror Switch (Without Door Trim) (C508) Power Mirror Switch (Without Door Trim) (C505) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 9548 Power Mirror Switch: Service and Repair REMOVAL 1. Pry the plate assembly upward. 2. Disconnect the electrical connector and remove the switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: Customer Interest Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: All Technical Service Bulletins Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9562 Driver's Seat Regulator Control Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9563 Power Seat Switch: Service Precautions WARNING THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG-EQUIPPED VEHICLE AND WHEN HANDLING A BELT AND BUCKLE ASSEMBLY PRETENSIONER. - THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. NEVER PROBE THE CONNECTORS ON THE BELT AND BUCKLE ASSEMBLY PRE TENSIONER. DOING SO CAN RESULT IN BELT AND BUCKLE ASSEMBLY PRETENSIONER OR AIR BAG DEPLOYMENT AND CAN RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF SO EQUIPPED). NOTE: Be sure to disconnect auxiliary batteries and power supplies (if so equipped). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9564 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable(s). WARNING THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG-EQUIPPED VEHICLE AND WHEN HANDLING A BELT AND BUCKLE ASSEMBLY PRETENSIONER. - THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. NEVER PROBE THE CONNECTORS ON THE BELT AND BUCKLE ASSEMBLY PRE TENSIONER. DOING SO CAN RESULT IN BELT AND BUCKLE ASSEMBLY PRETENSIONER OR AIR BAG DEPLOYMENT AND CAN RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF SO EQUIPPED). NOTE: Be sure to disconnect auxiliary batteries and power supplies (if so equipped). 2. Remove the front seat from the vehicle. 1 Remove the plastic bolt covers. 2 Remove the nuts and bolts. 3 Disconnect the belt and buckle assembly pretensioner connector. 4 Remove the front seat NOTE: The front seat does not need to be removed in order to remove the seat control switch, but it may be easier to access the wiring connector and switch fasteners if the seat is removed. 3. Disconnect the power seat control switch connector. 4. Remove the appropriate seat back latch cover to access the switch. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 9565 5. Remove the power seat control switch. 1 Pull the front seat back latch lower cover away from the seat. 2 Pull the power seat control switch connector through the seat cushion. 3 Remove the screws. 4 Remove the power seat control switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 05-22-16 > Nov > 05 > Suspension - Spring Tower Flange Cracking Strut / Shock Tower: Customer Interest Suspension - Spring Tower Flange Cracking TSB 05-22-16 11/14/05 SPRING TOWER WELD REPAIR AND REPLACEMENT PROCEDURE FORD: 1997-2006 E-350, E-450 This article supersedes TSB 05-1-1 to update the vehicle model years and service procedure. ISSUE Some higher-mileage E-350 and E-450 cutaway vans may exhibit cracks in the left or right spring tower flange. ACTION Certain front spring tower cracks can be repaired effectively by welding a reinforcement plate at the crack following the Service Procedure in this TSB. If the crack does not meet the criteria for this reinforcement plate repair, the spring tower should be replaced. SPRING TOWER CRACK REPAIR PROCEDURE NOTE SPRING TOWER CRACK REPAIR USING THE REINFORCEMENT PLATE WELD PROCEDURE SHOULD ONLY BE PERFORMED IF THE FOLLOWING CONDITIONS ARE MET. ^ The crack must exist in a location that is accessible and allows proper repair. Use the reinforcement plate procedure to repair areas where a welded reinforcement plate can be installed while maintaining adequate clearance to the spring and other components ^ The crack must have no branches. Flange edges shall be separated or misaligned by no more than 1/8" (3 mm) ^ LH front spring tower cracks must be no longer than 1.5" (38 mm) ^ RH front spring tower cracks must be no longer than 1.25" (32 mm) If any of the above conditions are not met, see the Spring Tower Replacement procedure at the end of this bulletin. EQUIPMENT REQUIRED ^ MIG welding equipment is required and should be capable of 150 amps or greater using ER70-6 welding wire ^ A straight or right angle die grinder is effective for repair preparation REINFORCEMENT PLATE REPAIR MATERIAL SPECIFICATION ^ Reinforcement plates used in this repair procedure can be made from low carbon steel of the correct grade and thickness, similar to the front spring tower. They should be roughly rectangular shape. Other shapes may be cut and used for improved fit to the affected area of the flange, or to provide improved reinforcement. Repairs to non-flat areas of the spring tower flange require reinforcement plates to be formed to fit the contour of the spring tower. In some cases, the service spring tower part may be suitable as a source for the reinforcement plate ^ The spring tower is made of low carbon steel (SAE J403, grade 1008-1010). Spring tower material thickness is approximately 0.19" (4.8 mm) ^ Reinforcement plate material thickness should be in the range of 0.18"- 0.23" (4.6-5.8 mm) Approximate reinforcement plate size should be 4" +/- 3/8" long, by 5/8" +/- 1/8" wide (102 +/- 10 mm long, by 16 mm +/- 3 mm wide) ^ Reinforcement plates should be uncoated, free of rust or oil, and have smooth edges and surfaces REPAIR PROCEDURE NOTE A REINFORCEMENT PLATE IS REQUIRED TO REPAIR EACH CRACK. 1. Disconnect the battery. Use precautions to protect vehicle and customer installed equipment from damage during welding. 2. Support the vehicle on a frame hoist. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 05-22-16 > Nov > 05 > Suspension - Spring Tower Flange Cracking > Page 9574 3. Remove the front wheel assembly on the side to be repaired. 4. Loosen the front shock absorber at upper attachment, or disconnect the front shock at the lower attachment, to permit the axle to move down so the spring can be removed. Remove the front spring upper retainer and the front spring. Refer to the E-Series Workshop Manual. If required for inspection or repair access, also remove the shock from vehicle. 5. Cover the wheel end, brake rotor and brake hoses with a welding blanket to protect from grinding debris and weld spatter. 6. Clean or de-grease spring tower and ensure that all cracks have been identified. Prepare suitably sized reinforcement plates for the repair. 7. LH only, if necessary for access, remove the rear most steering gear bolt and apply tape over the hole to protect it from weld spatter. 8. Remove frame wax or E-coat from the spring tower in the areas to be welded, with a straight or right angle die grinder with a Scotch-Brite(TM) (or similar pad) and wax and grease remover. Include areas of the flange where the reinforcement plate will be welded to the spring tower. Also, clean up the back or inboard side of the flange in the area to be repaired. 9. Use a small burr tool to grind along the crack and form a U-groove for weld metal deposit. The U-groove should extend from the trimmed flange to approximately 3/8" (10 mm) beyond the visible end of the crack. No more than 1 mm of the original metal thickness should remain in the ground area at the "bottom" of the U-groove. 10. Use a 36 grit 3" grinding disk and chamfer any sharp edges along the U-groove, and grind the spring tower flange edge smooth 1" (25 mm) on either side of the crack location. 11. Using a MIG welder, fill the crack from its termination back toward the initiation point at the trim edge of the spring tower flange. 12. Cool the repair weld with an air blast and inspect. 13. Grind the weld flush with the original outboard surface of the spring tower. The recommended grinding direction for this operation is perpendicular to the direction of crack. 14. Check the reinforcement plate for proper fit-up to the repaired area. 15. If access to the flange edge is good, position and clamp the reinforcement plate on the spring tower flange so that the plate's edge is flush with the flange edge (butt joint edge). NOTE IF ACCESS TO THE FLANGE EDGE IS POOR, POSITION AND CLAMP THE REINFORCEMENT PLATE ON THE SPRING TOWER FLANGE SO THAT THE PLATE'S EDGE IS SLIGHTLY INSIDE THE FLANGE EDGE (LAP JOINT EDGE). 16. Begin by tack welding the reinforcement plate in place starting at the plate's edges farthest from the crack. Check MIG welder torch access for the weld pass, then make a weld along the inside edge of the reinforcement plate. Vertical down weld direction is preferred when possible. 17. Recheck for proper fit-up, adjust as required, and then make another weld pass along the outside edge of the reinforcement plate. A vertical down weld direction is preferred when possible. 18. Cool the welded area with an air blast and inspect. If required, grind smooth to remove excess weld material and/or stress concentrations. 19. Apply corrosion inhibiting paint, Motorcraft Low Temperature Anti-Corrosion Coating (PM-12-A), to the repair area. 20. Reassemble the vehicle and secure fasteners to the proper torques, as specified in the Workshop Manual. NOTE VERIFY THE "T" SHAPED END OF THE UPPER SPRING RETAINER IS PROPERLY ENGAGED AND SEATED IN THE SLOT AT THE TOP OF THE SPRING TOWER BEFORE THE FASTENER IS SECURED. NOTE LH SIDE ONLY - IF STEERING GEAR BOLT WAS REMOVED, REAPPLY THREAD ADHESIVE TO THE BOLT BEFORE IT IS INSTALLED AND TORQUED. SPRING TOWER REPLACEMENT Spring Towers can be replaced if the above conditions for Spring Tower Repair are not met. These parts are for installation by a skilled welder at an appropriate vehicle repair facility according to the general frame welding guidelines in Section 502 of the E-Series Workshop Manual. Refer to TSB 97-4-7 for replacement of the Spring Tower to #1 cross member rivet with a bolt. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 05-22-16 > Nov > 05 > Suspension - Spring Tower Flange Cracking > Page 9575 NOTE IF THE HOLES AND MOUNTING FEATURES ON THE RIGHT HAND SIDE (RHS) SERVICE PART ONLY DO NOT LINE UP WITH THOSE ON THE ORIGINAL EQUIPMENT COMPONENTS, AND THE VEHICLE WAS BUILT FROM 1/19/2001 THROUGH 4/10/2001, THEN THE REPLACEMENT BOLT HOLE SHOULD BE DRILLED AS OUTLINED IN FIGURE 1. RHS SPRING TOWERS FOR VEHICLES BUILT PRIOR TO 1/19/2001 WILL REQUIRE DRILLING FOR THE RHS REPLACEMENT BOLT HOLE. RHS SPRING TOWERS FOR VEHICLES BUILT AFTER 4/10/2001 SHOULD NOT REQUIRE DRILLING FOR THE RHS REPLACEMENT BOLT HOLE. Parts Block WARRANTY STATUS: Information Only - Not Warrantable OASIS CODES: 304000 305000 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 05-22-16 > Nov > 05 > Suspension - Spring Tower Flange Cracking Strut / Shock Tower: All Technical Service Bulletins Suspension - Spring Tower Flange Cracking TSB 05-22-16 11/14/05 SPRING TOWER WELD REPAIR AND REPLACEMENT PROCEDURE FORD: 1997-2006 E-350, E-450 This article supersedes TSB 05-1-1 to update the vehicle model years and service procedure. ISSUE Some higher-mileage E-350 and E-450 cutaway vans may exhibit cracks in the left or right spring tower flange. ACTION Certain front spring tower cracks can be repaired effectively by welding a reinforcement plate at the crack following the Service Procedure in this TSB. If the crack does not meet the criteria for this reinforcement plate repair, the spring tower should be replaced. SPRING TOWER CRACK REPAIR PROCEDURE NOTE SPRING TOWER CRACK REPAIR USING THE REINFORCEMENT PLATE WELD PROCEDURE SHOULD ONLY BE PERFORMED IF THE FOLLOWING CONDITIONS ARE MET. ^ The crack must exist in a location that is accessible and allows proper repair. Use the reinforcement plate procedure to repair areas where a welded reinforcement plate can be installed while maintaining adequate clearance to the spring and other components ^ The crack must have no branches. Flange edges shall be separated or misaligned by no more than 1/8" (3 mm) ^ LH front spring tower cracks must be no longer than 1.5" (38 mm) ^ RH front spring tower cracks must be no longer than 1.25" (32 mm) If any of the above conditions are not met, see the Spring Tower Replacement procedure at the end of this bulletin. EQUIPMENT REQUIRED ^ MIG welding equipment is required and should be capable of 150 amps or greater using ER70-6 welding wire ^ A straight or right angle die grinder is effective for repair preparation REINFORCEMENT PLATE REPAIR MATERIAL SPECIFICATION ^ Reinforcement plates used in this repair procedure can be made from low carbon steel of the correct grade and thickness, similar to the front spring tower. They should be roughly rectangular shape. Other shapes may be cut and used for improved fit to the affected area of the flange, or to provide improved reinforcement. Repairs to non-flat areas of the spring tower flange require reinforcement plates to be formed to fit the contour of the spring tower. In some cases, the service spring tower part may be suitable as a source for the reinforcement plate ^ The spring tower is made of low carbon steel (SAE J403, grade 1008-1010). Spring tower material thickness is approximately 0.19" (4.8 mm) ^ Reinforcement plate material thickness should be in the range of 0.18"- 0.23" (4.6-5.8 mm) Approximate reinforcement plate size should be 4" +/- 3/8" long, by 5/8" +/- 1/8" wide (102 +/- 10 mm long, by 16 mm +/- 3 mm wide) ^ Reinforcement plates should be uncoated, free of rust or oil, and have smooth edges and surfaces REPAIR PROCEDURE NOTE A REINFORCEMENT PLATE IS REQUIRED TO REPAIR EACH CRACK. 1. Disconnect the battery. Use precautions to protect vehicle and customer installed equipment from damage during welding. 2. Support the vehicle on a frame hoist. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 05-22-16 > Nov > 05 > Suspension - Spring Tower Flange Cracking > Page 9581 3. Remove the front wheel assembly on the side to be repaired. 4. Loosen the front shock absorber at upper attachment, or disconnect the front shock at the lower attachment, to permit the axle to move down so the spring can be removed. Remove the front spring upper retainer and the front spring. Refer to the E-Series Workshop Manual. If required for inspection or repair access, also remove the shock from vehicle. 5. Cover the wheel end, brake rotor and brake hoses with a welding blanket to protect from grinding debris and weld spatter. 6. Clean or de-grease spring tower and ensure that all cracks have been identified. Prepare suitably sized reinforcement plates for the repair. 7. LH only, if necessary for access, remove the rear most steering gear bolt and apply tape over the hole to protect it from weld spatter. 8. Remove frame wax or E-coat from the spring tower in the areas to be welded, with a straight or right angle die grinder with a Scotch-Brite(TM) (or similar pad) and wax and grease remover. Include areas of the flange where the reinforcement plate will be welded to the spring tower. Also, clean up the back or inboard side of the flange in the area to be repaired. 9. Use a small burr tool to grind along the crack and form a U-groove for weld metal deposit. The U-groove should extend from the trimmed flange to approximately 3/8" (10 mm) beyond the visible end of the crack. No more than 1 mm of the original metal thickness should remain in the ground area at the "bottom" of the U-groove. 10. Use a 36 grit 3" grinding disk and chamfer any sharp edges along the U-groove, and grind the spring tower flange edge smooth 1" (25 mm) on either side of the crack location. 11. Using a MIG welder, fill the crack from its termination back toward the initiation point at the trim edge of the spring tower flange. 12. Cool the repair weld with an air blast and inspect. 13. Grind the weld flush with the original outboard surface of the spring tower. The recommended grinding direction for this operation is perpendicular to the direction of crack. 14. Check the reinforcement plate for proper fit-up to the repaired area. 15. If access to the flange edge is good, position and clamp the reinforcement plate on the spring tower flange so that the plate's edge is flush with the flange edge (butt joint edge). NOTE IF ACCESS TO THE FLANGE EDGE IS POOR, POSITION AND CLAMP THE REINFORCEMENT PLATE ON THE SPRING TOWER FLANGE SO THAT THE PLATE'S EDGE IS SLIGHTLY INSIDE THE FLANGE EDGE (LAP JOINT EDGE). 16. Begin by tack welding the reinforcement plate in place starting at the plate's edges farthest from the crack. Check MIG welder torch access for the weld pass, then make a weld along the inside edge of the reinforcement plate. Vertical down weld direction is preferred when possible. 17. Recheck for proper fit-up, adjust as required, and then make another weld pass along the outside edge of the reinforcement plate. A vertical down weld direction is preferred when possible. 18. Cool the welded area with an air blast and inspect. If required, grind smooth to remove excess weld material and/or stress concentrations. 19. Apply corrosion inhibiting paint, Motorcraft Low Temperature Anti-Corrosion Coating (PM-12-A), to the repair area. 20. Reassemble the vehicle and secure fasteners to the proper torques, as specified in the Workshop Manual. NOTE VERIFY THE "T" SHAPED END OF THE UPPER SPRING RETAINER IS PROPERLY ENGAGED AND SEATED IN THE SLOT AT THE TOP OF THE SPRING TOWER BEFORE THE FASTENER IS SECURED. NOTE LH SIDE ONLY - IF STEERING GEAR BOLT WAS REMOVED, REAPPLY THREAD ADHESIVE TO THE BOLT BEFORE IT IS INSTALLED AND TORQUED. SPRING TOWER REPLACEMENT Spring Towers can be replaced if the above conditions for Spring Tower Repair are not met. These parts are for installation by a skilled welder at an appropriate vehicle repair facility according to the general frame welding guidelines in Section 502 of the E-Series Workshop Manual. Refer to TSB 97-4-7 for replacement of the Spring Tower to #1 cross member rivet with a bolt. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 05-22-16 > Nov > 05 > Suspension - Spring Tower Flange Cracking > Page 9582 NOTE IF THE HOLES AND MOUNTING FEATURES ON THE RIGHT HAND SIDE (RHS) SERVICE PART ONLY DO NOT LINE UP WITH THOSE ON THE ORIGINAL EQUIPMENT COMPONENTS, AND THE VEHICLE WAS BUILT FROM 1/19/2001 THROUGH 4/10/2001, THEN THE REPLACEMENT BOLT HOLE SHOULD BE DRILLED AS OUTLINED IN FIGURE 1. RHS SPRING TOWERS FOR VEHICLES BUILT PRIOR TO 1/19/2001 WILL REQUIRE DRILLING FOR THE RHS REPLACEMENT BOLT HOLE. RHS SPRING TOWERS FOR VEHICLES BUILT AFTER 4/10/2001 SHOULD NOT REQUIRE DRILLING FOR THE RHS REPLACEMENT BOLT HOLE. Parts Block WARRANTY STATUS: Information Only - Not Warrantable OASIS CODES: 304000 305000 Disclaimer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 9591 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 9592 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 9593 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 9599 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 9600 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 9601 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9615 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9616 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9617 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9618 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9619 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9620 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9621 Attachment III - Technical Information Table of Contents Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9622 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9623 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9624 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9625 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9626 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9627 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9628 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9629 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9630 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9631 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9632 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9633 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9634 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9635 ERROR: stackunderflow OFFENDING COMMAND: begin STACK: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness Technical Service Bulletin # 08S01S1 Date: 080410 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9640 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS was activated February 6, 2008. FSA VIN LIST ACTIVATED? Yes, VIN lists are available through NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9641 ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. [New!] CLAIMS PREPARATION AND SUBMISSION ^ It is no longer necessary for dealers to manually enter labor operation times for vehicles built prior to the 1997 model year. ^ Enter claims using Direct Warranty Entry (DWE). ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. ^ Claiming Information for Electrical Grease II (Submit on same repair line as repair.) - Program Code: 08S01 - Misc. Expense: OTHER - Misc. Expense: $6.07 NOTE: Electrical Grease II can only be claimed when Labor Operation 08S01EE or 08S01GG is claimed. (Do not claim as "Normal Shop Supplies".) ^ Refer to ACESII manual for claims preparation and submission information. Enter claims using Direct Warranty Entry (DWE). Attachment II - Labor and Parts Information [New!] LABOR ALLOWANCES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9642 [New!] Vehicle Parts Application & Labor Operation Chart Description of Labor Operations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9643 [New!] PARTS REQUIREMENTS / ORDERING INFORMATION [New!] SEED STOCK PLAN Refer to Safety Recall 05S28 Supplement # 15 for seed stock plans. Dealers will be notified via DOES II when open ordering begins or if seed stock quantites change. NOTE: If any of the necessary parts are needed to service specific vehicles, contact the Special Service Support Center. Please be prepared to provide your P&A; Code, vehicle VIN and vehicle owner name. Questions regarding parts should be directed to the Special Service Support Center or E-mailed to. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment III - Technical Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9644 Table of Contents OVERVIEW This program involves removing the 4W1Z-14A411-BC Fused Jumper Harness (FJH) that was previously installed during service on the affected vehicles and installing a Universal Fused Jumper Harness (UFJH), or a new Speed Control Deactivation Switch (SCDS). NOTE: Do not perform an Interim Repair (SCDS Disconnect) on any of the affected vehicles in this program. Call the Special Service Support Center if you do not have the necessary parts to complete the final repairs. SPEED CONTROL DEACTIVATION SWITCH (SCDS) LOCATION In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder, but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-1 50/250/350 it may be necessary to lift the vehicle to disconnect the SCDS. Remove the electrical connector from the speed control deactivation switch and check the fused jumper harness connector end for the presence of brake fluid. Cut the tie straps from the fused jumper harness 4W1 Z-1 4A41 1-BC and remove the fused jumper harness. ^ If there is no evidence of brake fluid on the connector, install a Universal Fused Jumper Harness. ^ If there is the presence of brake fluid on the connector, replace the Speed Control Deactivation Switch. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9645 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 1. PARTS APPLICATION CHART UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the universal fused jumper harness (Part Number 8W7Z-14A411-C) to the SCDS and the vehicle harness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9646 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 2. LEAKING SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 3. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9647 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 6. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 4. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to new step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 7. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. 8. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 9. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 5. 10. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9648 11. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 6. 12. Reconnect the servo connector. 13. Release the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9649 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9650 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9651 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9652 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9653 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9658 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9668 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9669 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9670 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9671 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9672 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9673 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9674 Attachment III - Technical Information Table of Contents Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9675 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9676 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9677 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9678 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9679 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9680 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9681 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9682 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9683 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9684 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9685 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9686 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9687 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9688 ERROR: stackunderflow OFFENDING COMMAND: begin STACK: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness Technical Service Bulletin # 08S01S1 Date: 080410 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9693 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS was activated February 6, 2008. FSA VIN LIST ACTIVATED? Yes, VIN lists are available through NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9694 ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. [New!] CLAIMS PREPARATION AND SUBMISSION ^ It is no longer necessary for dealers to manually enter labor operation times for vehicles built prior to the 1997 model year. ^ Enter claims using Direct Warranty Entry (DWE). ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. ^ Claiming Information for Electrical Grease II (Submit on same repair line as repair.) - Program Code: 08S01 - Misc. Expense: OTHER - Misc. Expense: $6.07 NOTE: Electrical Grease II can only be claimed when Labor Operation 08S01EE or 08S01GG is claimed. (Do not claim as "Normal Shop Supplies".) ^ Refer to ACESII manual for claims preparation and submission information. Enter claims using Direct Warranty Entry (DWE). Attachment II - Labor and Parts Information [New!] LABOR ALLOWANCES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9695 [New!] Vehicle Parts Application & Labor Operation Chart Description of Labor Operations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9696 [New!] PARTS REQUIREMENTS / ORDERING INFORMATION [New!] SEED STOCK PLAN Refer to Safety Recall 05S28 Supplement # 15 for seed stock plans. Dealers will be notified via DOES II when open ordering begins or if seed stock quantites change. NOTE: If any of the necessary parts are needed to service specific vehicles, contact the Special Service Support Center. Please be prepared to provide your P&A; Code, vehicle VIN and vehicle owner name. Questions regarding parts should be directed to the Special Service Support Center or E-mailed to. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment III - Technical Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9697 Table of Contents OVERVIEW This program involves removing the 4W1Z-14A411-BC Fused Jumper Harness (FJH) that was previously installed during service on the affected vehicles and installing a Universal Fused Jumper Harness (UFJH), or a new Speed Control Deactivation Switch (SCDS). NOTE: Do not perform an Interim Repair (SCDS Disconnect) on any of the affected vehicles in this program. Call the Special Service Support Center if you do not have the necessary parts to complete the final repairs. SPEED CONTROL DEACTIVATION SWITCH (SCDS) LOCATION In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder, but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-1 50/250/350 it may be necessary to lift the vehicle to disconnect the SCDS. Remove the electrical connector from the speed control deactivation switch and check the fused jumper harness connector end for the presence of brake fluid. Cut the tie straps from the fused jumper harness 4W1 Z-1 4A41 1-BC and remove the fused jumper harness. ^ If there is no evidence of brake fluid on the connector, install a Universal Fused Jumper Harness. ^ If there is the presence of brake fluid on the connector, replace the Speed Control Deactivation Switch. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9698 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 1. PARTS APPLICATION CHART UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the universal fused jumper harness (Part Number 8W7Z-14A411-C) to the SCDS and the vehicle harness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9699 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 2. LEAKING SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 3. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9700 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 6. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 4. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to new step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 7. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. 8. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 9. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 5. 10. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9701 11. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 6. 12. Reconnect the servo connector. 13. Release the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9702 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9703 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9704 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9705 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9706 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9711 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 9712 Brake Switch (Cruise Control): Specifications Deactivator Switch ............................................................................................................................... ........................................... 15-20 N.m (11-14 Lb-Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 9713 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the deactivator switch electrical connector, and remove the deactivator switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. - After the deactivator switch is installed, it is necessary to bleed the brake system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9722 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9723 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9724 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9725 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9726 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9727 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9728 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9729 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9730 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9731 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9732 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9733 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9734 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9735 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9736 Owner Letter Owner Letter not available at this time. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9742 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9743 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9744 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9745 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9746 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9747 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9748 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9749 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9750 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9751 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9752 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9753 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9754 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9755 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9756 Owner Letter Owner Letter not available at this time. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams Speed Control Sensor/Amplifier Assembly Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications Cruise Control Servo: Specifications Speed Control Servo Bracket to Inner Fender Well Bolts .................................................................................................................. 10-13 N.m (7-9 Lb-Ft) Speed Control Servo to Bracket Bolts .............................................................................................................................................. 8-10 N.m (72-89 Lb-In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9763 Speed Control Sensor/Amplifier Assembly Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9764 Cruise Control Servo: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the engine air cleaner. 3. Remove the air cleaner outlet tube. 4. Remove the accelerator control splash shield. 5. Position the radiator coolant recovery reservoir aside. 1. Remove the bolts. 2. Position the radiator coolant recovery reservoir aside. 6. Detach the speed control servo from the inner fender well. 1. Disconnect the speed control servo electrical connector. 2. Remove the bolts to detach the speed control servo. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9765 7. Remove the speed control servo. 1. Press the locking tab in. 2. Rotate the speed control actuator cable cap and disconnect the speed control actuator cable. 3. Remove the speed control servo. 8. Detach the speed control servo from the bracket. 1. Remove the bolts. 2. Detach the speed control servo from the bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. - It is necessary to adjust the speed control actuator cable after the speed control servo is installed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair Cruise Control Servo Cable: Service and Repair REMOVAL 1. Remove the speed control servo. 2. Remove the speed control actuator cable. 1. Disconnect the speed control actuator cable from the throttle body cam. 2. Squeeze the retaining tabs and remove the speed control actuator cable. INSTALLATION 1. To install, reverse the removal procedure. NOTE: It is necessary to adjust the speed control actuator cable after installation is complete. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 9782 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the driver side air bag module. 2. Remove the speed control actuator switches. 1. Disconnect the speed control actuator switch electrical connector. 2. Remove the two bolts. 3. Remove the speed control actuator switches. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams Speed Control Sensor/Amplifier Assembly Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9800 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9801 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9802 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9803 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9804 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9805 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9806 Attachment III - Technical Information Table of Contents Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9807 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9808 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9809 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9810 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9811 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9812 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9813 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9814 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9815 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9816 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9817 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9818 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9819 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9820 ERROR: stackunderflow OFFENDING COMMAND: begin STACK: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness Technical Service Bulletin # 08S01S1 Date: 080410 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9825 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS was activated February 6, 2008. FSA VIN LIST ACTIVATED? Yes, VIN lists are available through NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9826 ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. [New!] CLAIMS PREPARATION AND SUBMISSION ^ It is no longer necessary for dealers to manually enter labor operation times for vehicles built prior to the 1997 model year. ^ Enter claims using Direct Warranty Entry (DWE). ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. ^ Claiming Information for Electrical Grease II (Submit on same repair line as repair.) - Program Code: 08S01 - Misc. Expense: OTHER - Misc. Expense: $6.07 NOTE: Electrical Grease II can only be claimed when Labor Operation 08S01EE or 08S01GG is claimed. (Do not claim as "Normal Shop Supplies".) ^ Refer to ACESII manual for claims preparation and submission information. Enter claims using Direct Warranty Entry (DWE). Attachment II - Labor and Parts Information [New!] LABOR ALLOWANCES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9827 [New!] Vehicle Parts Application & Labor Operation Chart Description of Labor Operations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9828 [New!] PARTS REQUIREMENTS / ORDERING INFORMATION [New!] SEED STOCK PLAN Refer to Safety Recall 05S28 Supplement # 15 for seed stock plans. Dealers will be notified via DOES II when open ordering begins or if seed stock quantites change. NOTE: If any of the necessary parts are needed to service specific vehicles, contact the Special Service Support Center. Please be prepared to provide your P&A; Code, vehicle VIN and vehicle owner name. Questions regarding parts should be directed to the Special Service Support Center or E-mailed to. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment III - Technical Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9829 Table of Contents OVERVIEW This program involves removing the 4W1Z-14A411-BC Fused Jumper Harness (FJH) that was previously installed during service on the affected vehicles and installing a Universal Fused Jumper Harness (UFJH), or a new Speed Control Deactivation Switch (SCDS). NOTE: Do not perform an Interim Repair (SCDS Disconnect) on any of the affected vehicles in this program. Call the Special Service Support Center if you do not have the necessary parts to complete the final repairs. SPEED CONTROL DEACTIVATION SWITCH (SCDS) LOCATION In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder, but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-1 50/250/350 it may be necessary to lift the vehicle to disconnect the SCDS. Remove the electrical connector from the speed control deactivation switch and check the fused jumper harness connector end for the presence of brake fluid. Cut the tie straps from the fused jumper harness 4W1 Z-1 4A41 1-BC and remove the fused jumper harness. ^ If there is no evidence of brake fluid on the connector, install a Universal Fused Jumper Harness. ^ If there is the presence of brake fluid on the connector, replace the Speed Control Deactivation Switch. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9830 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 1. PARTS APPLICATION CHART UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the universal fused jumper harness (Part Number 8W7Z-14A411-C) to the SCDS and the vehicle harness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9831 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 2. LEAKING SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 3. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9832 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 6. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 4. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to new step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 7. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. 8. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 9. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 5. 10. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9833 11. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 6. 12. Reconnect the servo connector. 13. Release the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9834 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9835 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9836 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9837 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9838 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9843 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9853 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9854 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9855 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9856 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9857 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9858 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9859 Attachment III - Technical Information Table of Contents Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9860 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9861 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9862 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9863 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9864 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9865 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9866 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9867 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9868 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9869 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9870 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9871 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9872 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9873 ERROR: stackunderflow OFFENDING COMMAND: begin STACK: Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness Technical Service Bulletin # 08S01S1 Date: 080410 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9878 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS was activated February 6, 2008. FSA VIN LIST ACTIVATED? Yes, VIN lists are available through NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9879 ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. [New!] CLAIMS PREPARATION AND SUBMISSION ^ It is no longer necessary for dealers to manually enter labor operation times for vehicles built prior to the 1997 model year. ^ Enter claims using Direct Warranty Entry (DWE). ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. ^ Claiming Information for Electrical Grease II (Submit on same repair line as repair.) - Program Code: 08S01 - Misc. Expense: OTHER - Misc. Expense: $6.07 NOTE: Electrical Grease II can only be claimed when Labor Operation 08S01EE or 08S01GG is claimed. (Do not claim as "Normal Shop Supplies".) ^ Refer to ACESII manual for claims preparation and submission information. Enter claims using Direct Warranty Entry (DWE). Attachment II - Labor and Parts Information [New!] LABOR ALLOWANCES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9880 [New!] Vehicle Parts Application & Labor Operation Chart Description of Labor Operations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9881 [New!] PARTS REQUIREMENTS / ORDERING INFORMATION [New!] SEED STOCK PLAN Refer to Safety Recall 05S28 Supplement # 15 for seed stock plans. Dealers will be notified via DOES II when open ordering begins or if seed stock quantites change. NOTE: If any of the necessary parts are needed to service specific vehicles, contact the Special Service Support Center. Please be prepared to provide your P&A; Code, vehicle VIN and vehicle owner name. Questions regarding parts should be directed to the Special Service Support Center or E-mailed to. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment III - Technical Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9882 Table of Contents OVERVIEW This program involves removing the 4W1Z-14A411-BC Fused Jumper Harness (FJH) that was previously installed during service on the affected vehicles and installing a Universal Fused Jumper Harness (UFJH), or a new Speed Control Deactivation Switch (SCDS). NOTE: Do not perform an Interim Repair (SCDS Disconnect) on any of the affected vehicles in this program. Call the Special Service Support Center if you do not have the necessary parts to complete the final repairs. SPEED CONTROL DEACTIVATION SWITCH (SCDS) LOCATION In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder, but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-1 50/250/350 it may be necessary to lift the vehicle to disconnect the SCDS. Remove the electrical connector from the speed control deactivation switch and check the fused jumper harness connector end for the presence of brake fluid. Cut the tie straps from the fused jumper harness 4W1 Z-1 4A41 1-BC and remove the fused jumper harness. ^ If there is no evidence of brake fluid on the connector, install a Universal Fused Jumper Harness. ^ If there is the presence of brake fluid on the connector, replace the Speed Control Deactivation Switch. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9883 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 1. PARTS APPLICATION CHART UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the universal fused jumper harness (Part Number 8W7Z-14A411-C) to the SCDS and the vehicle harness. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9884 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 2. LEAKING SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 3. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9885 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 6. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 4. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to new step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 7. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. 8. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 9. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 5. 10. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9886 11. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 6. 12. Reconnect the servo connector. 13. Release the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9887 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9888 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9889 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9890 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9891 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9896 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 9897 Brake Switch (Cruise Control): Specifications Deactivator Switch ............................................................................................................................... ........................................... 15-20 N.m (11-14 Lb-Ft) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 9898 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the deactivator switch electrical connector, and remove the deactivator switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. - After the deactivator switch is installed, it is necessary to bleed the brake system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9907 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9908 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9909 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9910 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9911 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9912 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9913 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9914 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9915 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9916 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9917 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9918 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9919 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9920 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9921 Owner Letter Owner Letter not available at this time. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9927 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9928 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9929 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9930 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9931 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9932 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9933 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9934 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9935 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9936 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9937 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9938 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9939 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9940 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9941 Owner Letter Owner Letter not available at this time. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 9955 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the driver side air bag module. 2. Remove the speed control actuator switches. 1. Disconnect the speed control actuator switch electrical connector. 2. Remove the two bolts. 3. Remove the speed control actuator switches. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: Customer Interest Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 9965 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: All Technical Service Bulletins Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 9971 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9974 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9975 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9976 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9977 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9978 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9979 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9980 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9981 Warning Chime Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 9982 Audible Warning Device: Description and Operation Chime/Buzzer The warning chime/buzzer module produces a repetitive chime or steady buzzing sound, for either a predetermined amount of time or continuously, under the following conditions: The driver safety belt is unbuckled and the ignition key is in RUN. - The key is in the ignition switch lock cylinder and the driver door is open. - The headlamp switch is in the READ or PARK position, the driver door is open and the key is not in the ignition switch lock cylinder. Seat Belt Warning The safety belt warning chime/buzzer reminds the driver to fasten the safety belt. This occurs when the ignition key is turned to RUN and the driver safety belt remains unbuckled. The chime/buzzer can be terminated by buckling the driver safety belt anytime during the 48 second chime/buzzer warning. The chime/buzzer works in conjunction with the safety belt warning indicator in the instrument cluster. When the ignition key is turned to RUN, the safety belt warning indicator will illuminate for five seconds, whether or not the driver safety belt is buckled, to perform a prove out on the bulb. Key-In-Ignition Warning The key-in-ignition warning chime/buzzer will sound continuously when the ignition key is in the ignition switch lock cylinder with the key OFF and the driver door open. The chime/buzzer will continue to sound until the key is removed from the ignition switch lock cylinder or the driver door is closed. Headlamps ON Warning On vehicles equipped with Headlamps ON Warning, the warning chime/buzzer will sound continuously when the headlamp switch is in the PARK or HEAD position, the driver door is open and the key is not in the ignition switch lock cylinder. The chime/buzzer will continue to sound until the headlamp switch is turned OFF or the driver door is closed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Audible Warning Device: Initial Inspection and Diagnostic Overview 1. Verify the concern by operating the warning chime/buzzer system to duplicate the concern. 2. Inspect to determine if one of the following electrical concerns applies. VISUAL INSPECTION CHART Electrical Fuses 2 (15 A), 4 (15 A) and 10 (20 A) - Loose or corroded connections - Circuits 3. If the concern(s) remains after the inspection, determine the symptom(s) and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9985 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9986 Audible Warning Device: Pinpoint Tests A1 - A2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9987 B1 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9988 B2 - B3 C: Key-In-Ignition Chime Doesn't Operate Properly Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9989 C1 - C2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9990 C3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9991 C4 - C5 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9992 C6 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9993 D1 - D2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9994 Special Service Tool(s) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Locations Audible Warning Device Control Module: Locations Instrument Panel Views The Warning Buzzer Module is located behind the centre of instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Locations > Page 9998 Warning Buzzer Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Service and Repair > Warning Buzzer Module (RV Only) Audible Warning Device Control Module: Service and Repair Warning Buzzer Module (RV Only) REMOVAL 1. Disconnect battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the engine cover. 3. Remove the warning buzzer module. 1 Rotate the buzzer module 90 degrees. 2 Pull the buzzer away from the bracket. 3 Disconnect the electrical connector from the buzzer and remove the buzzer module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Service and Repair > Warning Buzzer Module (RV Only) > Page 10001 Audible Warning Device Control Module: Service and Repair Warning Chime Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the engine cover. 3. Remove the warning chime module. 1 Slide the chime module off the bracket. 2 Disconnect the electrical connector and remove the chime module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10006 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10007 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10008 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10009 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10010 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10011 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10012 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10013 Cigar Lighter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect the battery ground cable(s). WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable(s). REACTIVATION PROCEDURE 1. Disconnect the battery ground cables. WARNING: THE AIR BAG SIMULATORS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Reconnect the passenger air bag module. 7. Reconnect the battery ground cable(s). 8. Prove out the system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 10019 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the primary crash sensor connected and mounted to the vehicle? [ ] 2. Is the three-way connector at the base of the steering column connected? [ ] 3. Are the air bag modules and belt and buckle assembly pretensioners or air bag simulators connected? [ ] 4. Is the air bag Electronic Crash Sensor (ECS) module connected? [ ] 5. Is the vehicle battery connected? [ ] Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1. Disconnect the electrical connector. 2. Rotate switch counterclockwise. 3. Remove the interior lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection Fuel Gauge: Testing and Inspection For Testing of this and other gauges, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Panel, Testing and Inspection. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Headlamp Reminder Indicator > Component Information > Description and Operation Headlamp Reminder Indicator: Description and Operation On vehicles equipped with Headlamps ON Warning, the warning chime/buzzer will sound continuously when the headlamp switch is in the PARK or HEAD position, the driver door is open and the key is not in the ignition switch lock cylinder. The chime/buzzer will continue to sound until the headlamp switch is turned OFF or the driver door is closed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect the battery ground cable(s). WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable(s). REACTIVATION PROCEDURE 1. Disconnect the battery ground cables. WARNING: THE AIR BAG SIMULATORS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait one minute for the backup power supply in the air bag Electronic Crash Sensor (ECS) module to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Reconnect the passenger air bag module. 7. Reconnect the battery ground cable(s). 8. Prove out the system. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 10034 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the primary crash sensor connected and mounted to the vehicle? [ ] 2. Is the three-way connector at the base of the steering column connected? [ ] 3. Are the air bag modules and belt and buckle assembly pretensioners or air bag simulators connected? [ ] 4. Is the air bag Electronic Crash Sensor (ECS) module connected? [ ] 5. Is the vehicle battery connected? [ ] Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 REMOVAL 1. Remove the instrument cluster. 2. Remove the instrument cluster illumination bulbs. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation The key-in-ignition warning chime/buzzer will sound continuously when the ignition key is in the ignition switch lock cylinder with the key OFF and the driver door open. The chime/buzzer will continue to sound until the key is removed from the ignition switch lock cylinder or the driver door is closed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Testing and Inspection Odometer: Testing and Inspection For Testing of this and other gauges, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Panel, Testing and Inspection. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection For Testing of this and other gauges, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Panel, Testing and Inspection. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection For testing procedures for the Transmission Control Indicator Lamp (TCIL), please refer to Pinpoint Test C in Automatic Transmission/Transaxle / Testing and Inspection / Procedures / External Control Diagnostics. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations Audible Warning Device Control Module: Locations Instrument Panel Views The Warning Buzzer Module is located behind the centre of instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations > Page 10054 Warning Buzzer Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair > Warning Buzzer Module (RV Only) Audible Warning Device Control Module: Service and Repair Warning Buzzer Module (RV Only) REMOVAL 1. Disconnect battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the engine cover. 3. Remove the warning buzzer module. 1 Rotate the buzzer module 90 degrees. 2 Pull the buzzer away from the bracket. 3 Disconnect the electrical connector from the buzzer and remove the buzzer module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair > Warning Buzzer Module (RV Only) > Page 10057 Audible Warning Device Control Module: Service and Repair Warning Chime Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the engine cover. 3. Remove the warning chime module. 1 Slide the chime module off the bracket. 2 Disconnect the electrical connector and remove the chime module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Testing and Inspection Speedometer Module: Testing and Inspection For Testing of this and other gauges, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Panel, Testing and Inspection. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation The safety belt warning chime/buzzer reminds the driver to fasten the safety belt. This occurs when the ignition key is turned to RUN and the driver safety belt remains unbuckled. The chime/buzzer can be terminated by buckling the driver safety belt anytime during the 48 second chime/buzzer warning. The chime/buzzer works in conjunction with the safety belt warning indicator in the instrument cluster. When the ignition key is turned to RUN, the safety belt warning indicator will illuminate for five seconds, whether or not the driver safety belt is buckled, to perform a prove out on the bulb. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation The safety belt warning chime/buzzer reminds the driver to fasten the safety belt. This occurs when the ignition key is turned to RUN and the driver safety belt remains unbuckled. The chime/buzzer can be terminated by buckling the driver safety belt anytime during the 48 second chime/buzzer warning. The chime/buzzer works in conjunction with the safety belt warning indicator in the instrument cluster. When the ignition key is turned to RUN, the safety belt warning indicator will illuminate for five seconds, whether or not the driver safety belt is buckled, to perform a prove out on the bulb. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1. Disconnect the electrical connector. 2. Rotate switch counterclockwise. 3. Remove the interior lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation The key-in-ignition warning chime/buzzer will sound continuously when the ignition key is in the ignition switch lock cylinder with the key OFF and the driver door open. The chime/buzzer will continue to sound until the key is removed from the ignition switch lock cylinder or the driver door is closed. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Place the transmission range selector lever into MANUAL 1 position, then back to the (D) position. 2. Hang a three-pound weight on the transmission range selector lever. 3. Center the pointer in the middle of the (D) position. - Rotate the thumb wheel, located on the bottom of the steering column, to adjust the pointer. 4. Remove the weight. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Testing and Inspection Speedometer Module: Testing and Inspection For Testing of this and other gauges, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Panel, Testing and Inspection. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection For Testing of this and other gauges, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Panel, Testing and Inspection. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications TORQUE SPECIFICATIONS Water Temperature Indicator Sender Unit ................................................................................................................................. 16-24 Nm (12-18 ft. lbs.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications > Page 10086 Temperature Sensor (Gauge): Locations Engine Views The Instrumentation Engine Coolant Temperature Sensor is located on the upper left front of engine. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications > Page 10087 Temperature Sensor (Gauge): Service and Repair REMOVAL 1. Remove the air cleaner assembly. 2. Partially drain the cooling system. 3. Disconnect the electrical connector. Remove the engine coolant temperature sensor from the intake manifold. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Testing and Inspection Volt Meter Gauge: Testing and Inspection For Testing of this and other gauges, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Panel, Testing and Inspection. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 10096 Backup Lamp Switch: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 10097 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10106 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10112 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10115 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10116 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10117 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10118 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10119 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10120 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10121 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10122 Brake Lamp: Electrical Diagrams Turn/Stop/Hazard Lamps (Part 1 Of 3) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10123 Turn/Stop/Hazard Lamps (Part 2 Of 3) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10124 Turn/Stop/Hazard Lamps (Part 3 Of 3) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Brake Lamp: Flow of Diagnosis 1. Verify the vehicle owner's original concern by operating the stoplamps to duplicate the original condition. 2. Inspect to determine if one of the following electrical concerns apply: VISUAL INSPECTION CHART Electrical Circuitry - Blown fuse junction panel Fuse 7 (10 A) and Fuse 11 (15 A) - Damaged multi-function switch - Damaged Brake Pedal Position (BPP) switch - Damaged Connectors 3. If the concern(s) remains after the inspection, determine the symptom(s) and proceed to the symptom chart. See: Symptom Related Diagnostic Procedures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10127 Brake Lamp: Initial Inspection and Diagnostic Overview 1. Verify the vehicle owner's original concern by operating the stoplamps to duplicate the original condition. 2. Inspect to determine if one of the following electrical concerns apply: VISUAL INSPECTION CHART Electrical Circuitry - Blown fuse junction panel Fuse 7 (10 A) and Fuse 11 (15 A) - Damaged multi-function switch - Damaged Brake Pedal Position (BPP) switch - Damaged Connectors 3. If the concern(s) remains after the inspection, determine the symptom(s) and proceed to the symptom chart. See: Symptom Related Diagnostic Procedures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10128 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10129 Brake Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. H Stoplamps Are Inop Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10130 H1 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10131 H2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10132 H3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10133 H4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10134 H5 - H6 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10135 J1 - J2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10136 K1 - K2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 10137 73 Digital Multimeter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation Brake Light Switch: Description and Operation Exterior Lighting System Components The stoplight switch controls the brake lamps, and rear hi-mount lamp. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 10141 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 3. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the brake master cylinder push rod spacer. 3 Remove the BPP switch from the brake master cylinder push rod. 4 Remove the brake master cylinder push rod bushing. 5 Remove the brake master cylinder push rod spacer. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > With Headliner Cargo Lamp: Service and Repair With Headliner REMOVAL 1. Remove the lens to interior lamp body (cargo lamp) screws. 2. Remove the interior lamp body (cargo lamp) screws. 3. Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > With Headliner > Page 10146 Cargo Lamp: Service and Repair Without Headliner REMOVAL 1. Remove the lens to interior lamp door (cargo lamp) screws. 2. Remove the interior lamp door (cargo lamp) screws. 3. Remove the bulb sockets from the rear hi-mount lamp and remove the interior lamp door. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10155 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling > Page 10161 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair > With Cargo Lamp Attached Center Mounted Brake Lamp: Service and Repair With Cargo Lamp Attached REMOVAL 1. Remove the rear hi-mount lamp screws. 2. Remove the screws retaining the lens to the interior lamp door (cargo lamp). 3. Remove the interior lamp door (cargo lamp) screws. 4. Remove the two bulb sockets and remove the rear hi-mount lamp assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair > With Cargo Lamp Attached > Page 10164 Center Mounted Brake Lamp: Service and Repair Without Cargo Lamp Attached REMOVAL 1. Remove the rear hi-mount lamp screws. 2. Remove the rear hi-mount lamp. 3. Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions Courtesy Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10169 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10170 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10171 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10172 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10173 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10174 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10175 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10176 Courtesy Lamp: Electrical Diagrams Courtesy Lamps Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10177 Courtesy Lamps Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10178 Courtesy Lamps Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10179 Courtesy Lamps (With Full Headliner) (Part 1 Of 2) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10180 Courtesy Lamps Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10181 Courtesy Lamps Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Page 10182 Courtesy Lamp: Description and Operation Interior Lighting Components Courtesy Lamps The interior lamps are located on the roof trim panel. The interior lamps are energized anytime the lamp switches are activated or when the headlamp switch is turned counterclockwise to the stop position. Illuminated Entry The illuminated entry activates the interior lamps anytime the door handle is pulled to the open position. The length of time the illuminated entry system is energized is controlled by the illuminated entry module. The illuminated entry feature will be canceled when any of the following conditions are met: 25 seconds have elapsed since the illuminated entry feature was activated and the interior lamp control is turned off. - The ignition is in the RUN or START position, and the interior lamp control is not activated. On vehicles equipped with an optional remote keyless entry system, the functions of the illuminated entry module are performed by the Remote Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Page 10183 Keyless Entry (RKE) module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications Daytime Running Lamp Control Module Bolts ........................................................................................................................... Nm (2.6-3.2 23-28 Lb-In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10188 Daytime Running Lamp Control Unit: Locations Engine Compartment Views The Daytime Running Lamps Module is located at the RH front of engine, near horns. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10189 Daytime Running Lamps Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10190 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Remove the A/C condenser air deflector. 1 Remove the six pushpins. 2 Remove the A/C condenser air deflector. 2. Remove the Daytime Running Lamps (DRL) control module. 1 Remove the bolts. 2 Disconnect the DRL control module connector 3 Remove the DRL control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior Dome Lamp Dome Lamp: Service and Repair Interior Dome Lamp REMOVAL 1. Pry the interior lamp (dome lamp) assembly from the headliner. 2. Disconnect the interior lamp (dome lamp) assembly electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior Dome Lamp > Page 10195 Dome Lamp: Service and Repair Interior Dome/Reading Lamp REMOVAL 1. Rotate both dome/reading lamps to the stop position, then continue until both dome/reading lamps are in the vertical position. 2. Remove the dome/reading lamp screws. 3. Disconnect the dome/reading lamp electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1. Disconnect the electrical connector. 2. Rotate switch counterclockwise. 3. Remove the interior lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations Instrument Panel Views The Electronic Flasher is located behind LH side of the instrument panel, on electronic flasher. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 10206 Hazard Warning Switch: Diagrams Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 10207 Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 10208 Hazard Warning Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. - Ignition. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis Hazard Warning Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10211 Hazard Warning Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10212 Hazard Warning Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10213 Hazard Warning Switch: Pinpoint Tests Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10214 C1 Part 2 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10215 Part 3 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10216 Hazard Warning Switch: Component Tests and General Diagnostics Terminals Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10217 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10218 1. Measure the resistance between the multi-function switch terminals. - If the resistances are as specified, the multi-function switch is OK. Return the multi-function switch to the vehicle. Test the system for normal operation. - If the resistances are not as specified, replace the multi-function switch. Test the system for normal operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 10219 Hazard Warning Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 4. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 10220 5. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Technician Safety Information Headlamp Bulb: Technician Safety Information WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Technician Safety Information > Page 10226 Headlamp Bulb: Vehicle Damage Warnings NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement 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 headlamps with the bulb removed from the headlamp. CAUTION: Bulbs No.9006 and No.9007 look similar, but are not interchangeable. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Page 10227 Headlamp Bulb: Service and Repair With Aerodynamic Headlamp Assembly REMOVAL WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement 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 headlamps with the bulb removed from the headlamp. 1. Remove the aerodynamic headlamp assembly. 2. Remove the headlamp bulb. 1 Rotate the headlamp bulb retainer counterclockwise one-eighth turn. 2 Remove the headlamp bulb. INSTALLATION CAUTION: Bulbs No.9006 and No.9007 look similar, but are not interchangeable. 1. Install the headlamp bulb. 1 Install the headlamp bulb. 2 Rotate the headlamp bulb retainer clockwise one-eighth turn. 2. Install the aerodynamic headlamp assembly. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 10231 Headlamp Dimmer Switch: Diagrams Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 10232 Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 10233 Headlamp Dimmer Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. - Ignition. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Headlamp Dimmer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10236 Headlamp Dimmer Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10237 Headlamp Dimmer Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10238 Headlamp Dimmer Switch: Pinpoint Tests Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10239 C1 Part 2 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10240 Part 3 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10241 Headlamp Dimmer Switch: Component Tests and General Diagnostics Terminals Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10242 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10243 1. Measure the resistance between the multi-function switch terminals. - If the resistances are as specified, the multi-function switch is OK. Return the multi-function switch to the vehicle. Test the system for normal operation. - If the resistances are not as specified, replace the multi-function switch. Test the system for normal operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10244 Headlamp Dimmer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 4. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10245 5. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams Main Light Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10249 Headlamp Switch: Description and Operation Exterior Lighting System Components The headlamp switch is a three-position switch that controls the headlamps, exterior lamps, and panel lamps. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10250 Headlamp Switch: Testing and Inspection Main Light Switch-Component Testing Procedure Main Light Switch - Terminal Locations Main Light Switch - Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10251 Headlamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 3. Remove the headlamp switch bolts. 4. Disconnect the electrical connector and remove the headlamp switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations The Horn Relay is located in the Engine Compartment Fuse Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10256 Horn Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10257 Horn Relay: Testing and Inspection NOTE: Use three No. 10 (or larger gauge) jumper wires and 73 Digital Multimeter to test the horn relay. 1. Remove the relay from the power distribution box. 2. Using a multimeter, measure the resistance between Terminal 85 and all other terminals. If the resistance is 5 ohms or less, replace the relay. If the resistance is greater than 5 ohms, continue the test. 3. Use two jumper wires to connect Terminals 86 and 30 directly to the positive battery terminal. 4. Set the 73 digital multimeter in the volts position and check for voltage at Terminal 87 A. If battery voltage is not indicated, replace the relay. 5. If battery voltage is indicated, connect the third jumper wire to Terminal 85 and a known good ground. Check for voltage at Terminal 87. If battery voltage is not indicated, replace the relay. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations Interior Lighting Module: Locations Instrument Panel Views The Illuminated Entry Module is located behind the LH side of the instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 10261 Illuminated Entry Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 10262 Interior Lighting Module: Description and Operation Interior Lighting Components Illuminated Entry Module The illuminated entry module activates the interior lamps anytime the door handle is pulled to the open position. The length of time the illuminated entry system is energized is controlled by the illuminated entry module. The illuminated entry feature will be canceled when any of the following conditions are met: 25 seconds have elapsed since the illuminated entry feature was activated and the interior lamp control is turned off. - The ignition is in the RUN or START position, and the interior lamp control is not activated. On vehicles equipped with an optional remote keyless entry system, the functions of the illuminated entry module are performed by the Remote Keyless Entry (RKE) module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 10263 Interior Lighting Module: Service and Repair REMOVAL CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damages may result. 1. Disconnect the battery ground cable. 2. Remove the engine cover. 3. Remove the illuminated entry module. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the illuminated entry module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10268 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10269 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10270 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10271 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10272 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10273 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10274 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10275 Exterior Lamps Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis License Plate Lamp: Flow of Diagnosis 1. Verify the vehicle owner's original concern by operating the parking lamps to duplicate the original condition, 2. Inspect to determine if one of the following electrical concerns apply: VISUAL INSPECTION CHART Electrical Circuitry - Damaged connector - Bulb - Damaged headlamp switch - Blown fuse junction panel Fuse 10 (20 A) 3. If the concern(s) remains after the inspection, determine the symptom(s) and proceed to the symptom chart. See: Symptom Related Diagnostic Procedures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10278 License Plate Lamp: Initial Inspection and Diagnostic Overview 1. Verify the vehicle owner's original concern by operating the parking lamps to duplicate the original condition, 2. Inspect to determine if one of the following electrical concerns apply: VISUAL INSPECTION CHART Electrical Circuitry - Damaged connector - Bulb - Damaged headlamp switch - Blown fuse junction panel Fuse 10 (20 A) 3. If the concern(s) remains after the inspection, determine the symptom(s) and proceed to the symptom chart. See: Symptom Related Diagnostic Procedures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10279 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10280 License Plate Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. P Parking, Rear or License Lamps Inoperative Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10281 P1 - P2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10282 P3 - P4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10283 Q1 - Q2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10284 R1 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10285 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10290 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10291 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10292 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10293 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10294 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10295 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10296 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10297 Exterior Lamps Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10302 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10303 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10304 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10305 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10306 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10307 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10308 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10309 Exterior Lamps Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Parking Lamp: Flow of Diagnosis 1. Verify the vehicle owner's original concern by operating the parking lamps to duplicate the original condition, 2. Inspect to determine if one of the following electrical concerns apply: VISUAL INSPECTION CHART Electrical Circuitry - Damaged connector - Bulb - Damaged headlamp switch - Blown fuse junction panel Fuse 10 (20 A) 3. If the concern(s) remains after the inspection, determine the symptom(s) and proceed to the symptom chart. See: Symptom Related Diagnostic Procedures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10312 Parking Lamp: Initial Inspection and Diagnostic Overview 1. Verify the vehicle owner's original concern by operating the parking lamps to duplicate the original condition, 2. Inspect to determine if one of the following electrical concerns apply: VISUAL INSPECTION CHART Electrical Circuitry - Damaged connector - Bulb - Damaged headlamp switch - Blown fuse junction panel Fuse 10 (20 A) 3. If the concern(s) remains after the inspection, determine the symptom(s) and proceed to the symptom chart. See: Symptom Related Diagnostic Procedures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10313 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10314 Parking Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. P Parking, Rear or License Lamps Inoperative Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10315 P1 - P2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10316 P2 - P4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10317 Q1 - Q2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10318 R1 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10319 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Page 10320 Parking Lamp: Service and Repair REMOVAL NOTE: RH shown; LH similar. 1. Remove the parking lamp screws. 2. Pull the parking lamp forward and disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications Daytime Running Lamp Control Module Bolts ........................................................................................................................... Nm (2.6-3.2 23-28 Lb-In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10325 Daytime Running Lamp Control Unit: Locations Engine Compartment Views The Daytime Running Lamps Module is located at the RH front of engine, near horns. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10326 Daytime Running Lamps Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10327 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Remove the A/C condenser air deflector. 1 Remove the six pushpins. 2 Remove the A/C condenser air deflector. 2. Remove the Daytime Running Lamps (DRL) control module. 1 Remove the bolts. 2 Disconnect the DRL control module connector 3 Remove the DRL control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations The Horn Relay is located in the Engine Compartment Fuse Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10331 Horn Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10332 Horn Relay: Testing and Inspection NOTE: Use three No. 10 (or larger gauge) jumper wires and 73 Digital Multimeter to test the horn relay. 1. Remove the relay from the power distribution box. 2. Using a multimeter, measure the resistance between Terminal 85 and all other terminals. If the resistance is 5 ohms or less, replace the relay. If the resistance is greater than 5 ohms, continue the test. 3. Use two jumper wires to connect Terminals 86 and 30 directly to the positive battery terminal. 4. Set the 73 digital multimeter in the volts position and check for voltage at Terminal 87 A. If battery voltage is not indicated, replace the relay. 5. If battery voltage is indicated, connect the third jumper wire to Terminal 85 and a known good ground. Check for voltage at Terminal 87. If battery voltage is not indicated, replace the relay. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations Interior Lighting Module: Locations Instrument Panel Views The Illuminated Entry Module is located behind the LH side of the instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 10336 Illuminated Entry Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 10337 Interior Lighting Module: Description and Operation Interior Lighting Components Illuminated Entry Module The illuminated entry module activates the interior lamps anytime the door handle is pulled to the open position. The length of time the illuminated entry system is energized is controlled by the illuminated entry module. The illuminated entry feature will be canceled when any of the following conditions are met: 25 seconds have elapsed since the illuminated entry feature was activated and the interior lamp control is turned off. - The ignition is in the RUN or START position, and the interior lamp control is not activated. On vehicles equipped with an optional remote keyless entry system, the functions of the illuminated entry module are performed by the Remote Keyless Entry (RKE) module. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 10338 Interior Lighting Module: Service and Repair REMOVAL CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damages may result. 1. Disconnect the battery ground cable. 2. Remove the engine cover. 3. Remove the illuminated entry module. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the illuminated entry module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations The trailer lamp relays are located in the Engine Compartment Fuse Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay Trailer Backup Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 10344 Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 10345 Trailer Running Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Transmission View The Digital Transmission Range Sensor (4R70W) is located at the LH side of the transmission. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 10350 Backup Lamp Switch: Diagrams Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 10351 Digital Transmission Range Sensor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation Brake Light Switch: Description and Operation Exterior Lighting System Components The stoplight switch controls the brake lamps, and rear hi-mount lamp. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 10355 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 3. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the brake master cylinder push rod spacer. 3 Remove the BPP switch from the brake master cylinder push rod. 4 Remove the brake master cylinder push rod bushing. 5 Remove the brake master cylinder push rod spacer. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1. Disconnect the electrical connector. 2. Rotate switch counterclockwise. 3. Remove the interior lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 10362 Hazard Warning Switch: Diagrams Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 10363 Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 10364 Hazard Warning Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. - Ignition. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis Hazard Warning Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10367 Hazard Warning Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10368 Hazard Warning Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10369 Hazard Warning Switch: Pinpoint Tests Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10370 C1 Part 2 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10371 Part 3 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10372 Hazard Warning Switch: Component Tests and General Diagnostics Terminals Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10373 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10374 1. Measure the resistance between the multi-function switch terminals. - If the resistances are as specified, the multi-function switch is OK. Return the multi-function switch to the vehicle. Test the system for normal operation. - If the resistances are not as specified, replace the multi-function switch. Test the system for normal operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 10375 Hazard Warning Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 4. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 10376 5. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 10380 Headlamp Dimmer Switch: Diagrams Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 10381 Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 10382 Headlamp Dimmer Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. - Ignition. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Headlamp Dimmer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10385 Headlamp Dimmer Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10386 Headlamp Dimmer Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10387 Headlamp Dimmer Switch: Pinpoint Tests Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10388 C1 Part 2 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10389 Part 3 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10390 Headlamp Dimmer Switch: Component Tests and General Diagnostics Terminals Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10391 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10392 1. Measure the resistance between the multi-function switch terminals. - If the resistances are as specified, the multi-function switch is OK. Return the multi-function switch to the vehicle. Test the system for normal operation. - If the resistances are not as specified, replace the multi-function switch. Test the system for normal operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10393 Headlamp Dimmer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 4. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10394 5. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Main Light Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10398 Headlamp Switch: Description and Operation Exterior Lighting System Components The headlamp switch is a three-position switch that controls the headlamps, exterior lamps, and panel lamps. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10399 Headlamp Switch: Testing and Inspection Main Light Switch-Component Testing Procedure Main Light Switch - Terminal Locations Main Light Switch - Schematic Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10400 Headlamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 3. Remove the headlamp switch bolts. 4. Disconnect the electrical connector and remove the headlamp switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 10404 Turn Signal Switch: Diagrams Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 10405 Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 10406 Turn Signal Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. - Ignition. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis Turn Signal Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10409 Turn Signal Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10410 Turn Signal Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10411 Turn Signal Switch: Component Tests and General Diagnostics Terminals Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10412 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10413 1. Measure the resistance between the multi-function switch terminals. - If the resistances are as specified, the multi-function switch is OK. Return the multi-function switch to the vehicle. Test the system for normal operation. - If the resistances are not as specified, replace the multi-function switch. Test the system for normal operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 10414 Turn Signal Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 4. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 10415 5. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Tail Lamp: Flow of Diagnosis 1. Verify the vehicle owner's original concern by operating the parking lamps to duplicate the original condition, 2. Inspect to determine if one of the following electrical concerns apply: VISUAL INSPECTION CHART Electrical Circuitry - Damaged connector - Bulb - Damaged headlamp switch - Blown fuse junction panel Fuse 10 (20 A) 3. If the concern(s) remains after the inspection, determine the symptom(s) and proceed to the symptom chart. See: Symptom Related Diagnostic Procedures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10420 Tail Lamp: Initial Inspection and Diagnostic Overview 1. Verify the vehicle owner's original concern by operating the parking lamps to duplicate the original condition, 2. Inspect to determine if one of the following electrical concerns apply: VISUAL INSPECTION CHART Electrical Circuitry - Damaged connector - Bulb - Damaged headlamp switch - Blown fuse junction panel Fuse 10 (20 A) 3. If the concern(s) remains after the inspection, determine the symptom(s) and proceed to the symptom chart. See: Symptom Related Diagnostic Procedures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10421 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10422 Tail Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. P Parking, Rear or License Lamps Inop Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10423 P1 - P2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10424 P3 - P4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10425 Q1 - Q2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10426 R1 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10427 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Page 10428 Tail Lamp: Service and Repair REMOVAL NOTE: RH shown; LH similar. 1. Remove the rear lamp screws. 2. Pull the rear lamp forward. 3. Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10433 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10434 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10435 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10436 ELECTRICAL SYMBOLS Electrical Symbols Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10437 Electrical Symbols VACUUM SYMBOLS Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10438 Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10439 DG: Dark Green GY: Gray GN: Green LB: Light Blue LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10440 Trailer Lamps: Electrical Diagrams Trailer/Camper Adapter - With Auxiliary Battery Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10441 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10442 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10443 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10444 Trailer/Camper Adapter - Without Auxiliary Battery Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10445 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10446 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10447 Trailer/Camper Adapter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis Trailer Lamps: Flow of Diagnosis 1. Check the trailer feed wiring and the added trailer connector for obvious signs of damage. 2. Check the fuses and relays for damage. 3. If the concern remains after the inspection, determine the symptom(s) and proceed to the symptom chart. See: Symptom Related Diagnostic Procedures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10450 Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Check the trailer feed wiring and the added trailer connector for obvious signs of damage. 2. Check the fuses and relays for damage. 3. If the concern remains after the inspection, determine the symptom(s) and proceed to the symptom chart. See: Symptom Related Diagnostic Procedures Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10451 73 Digital Multimeter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10452 Trailer Lamps: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10453 AA1 - AA2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10454 AA3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10455 W1 - W2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10456 X1 - X2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10457 Y1 - Y3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10458 Y4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10459 Z1 - Z2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10460 Z3 - Z4 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10461 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations The trailer lamp relays are located in the Engine Compartment Fuse Box. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay Trailer Backup Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 10467 Trailer Battery Charge Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 10468 Trailer Running Lamp Relay Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations Instrument Panel Views The Electronic Flasher is located behind LH side of the instrument panel, on electronic flasher. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 10476 Turn Signal Switch: Diagrams Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 10477 Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 10478 Turn Signal Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. - Ignition. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis Turn Signal Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10481 Turn Signal Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10482 Turn Signal Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10483 Turn Signal Switch: Component Tests and General Diagnostics Terminals Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10484 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10485 1. Measure the resistance between the multi-function switch terminals. - If the resistances are as specified, the multi-function switch is OK. Return the multi-function switch to the vehicle. Test the system for normal operation. - If the resistances are not as specified, replace the multi-function switch. Test the system for normal operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 10486 Turn Signal Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 4. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 10487 5. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Switch Master Window/Door Lock Control Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Switch > Page 10494 RH Power Door Lock/Window Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Driver Side Power Window Switch: Description and Operation Driver Side The master window regulator control switch is located on the driver side front door trim panel and can be used to activate all of the power windows. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Driver Side > Page 10497 Power Window Switch: Description and Operation Passenger Side A single window regulator control switch is located on the passenger side front door trim panel. This window regulator control switch allows activation of the power window for that door only. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Page 10498 Power Window Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Carefully pry the window regulator switch plate up. 3. Remove the two screws. 4. Carefully pry up and remove the window regulator control switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Specifications Power Window Motor: Specifications Window Down (Under Load) ............................................................................................................... .................................................................. 4-8 Amps Window Up (Under Load) ................................. ................................................................................................................................................... 5-10 Amps Motor Stall ................................................................................................................................. .............................................................................. 14 Amps No Load ................................................. ................................................................................................................. 4 Amps Maximum With No Fluctuation Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Specifications > Page 10503 Power Window Motor: Service and Repair Heavy Duty Riverter Special Tool(s) REMOVAL 1. Disconnect the battery ground cable. 2. Remove the door handle bezel. 3. Remove the power window/door lock switch bezel, if so equipped. 4. Remove the rearview mirror fastener trim cover. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Specifications > Page 10504 5. Remove the door panel trim retaining screws. 6. Lift the door trim panel up from the door to disengage the trim panel clips. 7. Remove the courtesy lamp wiring harness connector and remove the door trim panel. 8. Disconnect the electrical connector. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Specifications > Page 10505 9. Remove the center pins from the rivets, using a drift. Using a 1/4-inch diameter drill, drill out the rivets attaching the window regulator electric drive bracket to the inner panel. NOTE: Use care not to enlarge the sheet metal holes in the door inner panel. 10. Working through the access hole, remove the window regulator electric drive bracket from the inner panel. - Rotate to gain access to the three screws retaining the window regulator electric drive to the bracket and cable drum housing. 11. Remove the screws, and separate the window regulator electric drive from the bracket and cable drum. 12. Remove the window regulator electric drive. INSTALLATION 1. Follow the removal procedure in reverse order. - Use the Heavy Duty Riveter to install the rivets (W525172-S). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Switch Master Window/Door Lock Control Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Switch > Page 10510 RH Power Door Lock/Window Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Driver Side Power Window Switch: Description and Operation Driver Side The master window regulator control switch is located on the driver side front door trim panel and can be used to activate all of the power windows. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Driver Side > Page 10513 Power Window Switch: Description and Operation Passenger Side A single window regulator control switch is located on the passenger side front door trim panel. This window regulator control switch allows activation of the power window for that door only. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Page 10514 Power Window Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Carefully pry the window regulator switch plate up. 3. Remove the two screws. 4. Carefully pry up and remove the window regulator control switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair Heavy Duty Riverter Special Tool(s) REMOVAL WARNING: ALWAYS WEAR SAFETY GLASSES AND GLOVES WHEN HANDLING GLASS TO AVOID PERSONAL INJURY. 1. Remove the front door trim panel. 2. Remove the front door belt line inside weatherstrip. 3. Remove the rear glass channel bolt, and lift the channel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Page 10519 4. Lower the window glass to gain access to the two glass bracket retaining rivets. 5. Remove the center pins from the rivets, using a drift. Using a 1/4-inch diameter drill, drill out the remainder of the rivets. CAUTION: Do not attempt to pry out the rivets, as damage to the front door window glass can result. Prior to removing the rivet center pins, it is recommended that a suitable block support be placed between the front door outer panel and the glass bracket to stabilize the glass during rivet removal. 6. Lift up and rotate the front door window glass clockwise, and remove. INSTALLATION 1. Follow the removal procedure in reverse order. - Use the Heavy Duty Riveter to install the rivets (W525172-S). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) 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 Heavy Duty Riverter Special Tool(s) REMOVAL 1. Remove the front door window glass. 2. Remove the window regulator electric drive (if so equipped). 3. Remove the center pins from the rivets, using a drift. Using a 1/4-inch diameter drill, drill out the rivets attaching the window regulator lower bracket to the inner panel. NOTE: Use care not to enlarge the sheet metal holes in the door inner panel. 4. Remove the nuts retaining the window regulator upper bracket to the door inner panel. 5. Remove the window regulator. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 10524 1. Follow the removal procedure in reverse order. - Use the Heavy Duty Riveter to install the rivets (W525172-S). Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Window Regulator Bracket Upper Nuts ......................................................................................................................................... 8-14 Nm (71-124 Lb-In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 98-18-3 > Sep > 98 > Power Door Locks/Keyless Entry - Inoperative When Wet Window Seal: Customer Interest Power Door Locks/Keyless Entry - Inoperative When Wet Article No. 98-18-3 09/14/98 ^ WATER LEAKS - ONTO REAR DOOR POWER LOCK SWITCH ^ POWER DOOR LOCKS - SELF ACTIVATE OR INOPERATIVE WHEN VEHICLE IS WET ^ REMOTE KEYLESS ENTRY - INOPERATIVE WHEN VEHICLE IS WET LIGHT TRUCK: 1996-98 ECONOLINE ISSUE Power door locks self activate, are inoperative, or remote keyless entry may be inoperative when vehicle is or has been wet. Water leaks onto the rear door power lock switch. This may be caused by: ^ Low torque on the door glass nuts ^ Door glass butyl rope seal off location ^ Porosity in sealant between the door seal C-channel-to-door sheet metal ^ Water entering inside the door from the hinges or check strap ACTION Repair leak and/or install water shield. Refer to the following Service Procedure for details. NOTE IF THE POWER LOCKS/REMOTE KEYLESS ENTRY ARE INOPERATIVE OR SELF-ACTIVATING AT THE TIME OF REPAIR, APPLICABILITY OF THIS TSB MAY BE CONFIRMED BY DISCONNECTING THE REAR DOOR SWITCH AND RETESTING. IF THE POWER LOCKS FUNCTION NORMALLY, THIS TSB WILL CORRECT THE CONCERN. SERVICE PROCEDURE Remove the interior trim halo moulding and door trim panel from the right rear door by referring to the procedures in the 1998 Econoline Workshop Manual, Pages 501-05-11 to 13. Perform the following Rear Door Glass, Door Seal C-Channel, and Door Hinges And Check Strap leak tests and repair procedures. NOTE VEHICLE MAY SELF-LOCK DURING WATER TEST. BE SURE KEYS ARE ACCESSIBLE. REAR DOOR GLASS Using water hose, direct water around the edge of the right rear door. Inspect for water leaks. If the door glass leaks, retighten nuts to 2.5 N.m (22 lb-in). If retightening the glass nuts does not stop the leak, replace the Rear Door Glass Module (F6UZ-15420A034-AA). DOOR SEAL C-CHANNEL Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 98-18-3 > Sep > 98 > Power Door Locks/Keyless Entry - Inoperative When Wet > Page 10536 Inspect for gaps and holes in the factory applied sealer along the outboard side of the C-channel (Figure 1) (weatherstrip is pulled out of C-channel in Figure 1). Using a water bottle, force water into any hole to see if a leak occurs, allowing water to exit the opposite side of the C-channel. Adjust hose to spray pattern and direct water across the rear end of the roof and at the top of the door. Inspect for water leaks. If leaks are found using either test, reseal the entire length of each side of the C-channel to the door sheet metal using clear silicone sealant. DOOR HINGES AND CHECK STRAP Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 98-18-3 > Sep > 98 > Power Door Locks/Keyless Entry - Inoperative When Wet > Page 10537 The hinges and check strap are not sealed and leaks are always expected. Install a Water Shield (XC2Z-15402A08-AA) to the door sheet metal (Figure 2). Route the switch wiring and connector under the bottom edge of the water shield (Figure 3). Be careful the water shield is not pulled loose by the wiring. PART NUMBER PART NAME XC2Z-15402A08-AA Water Shield F6UZ-15420A34-AA Rear Door Glass Module OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981803A Inspect For Water Leaks 1.3 Hrs. And Perform Repairs DEALER CODING CONDITION BASIC PART NO. CODE 14017 07 OASIS CODES: 110000, 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 98-18-3 > Sep > 98 > Power Door Locks/Keyless Entry Inoperative When Wet Window Seal: All Technical Service Bulletins Power Door Locks/Keyless Entry - Inoperative When Wet Article No. 98-18-3 09/14/98 ^ WATER LEAKS - ONTO REAR DOOR POWER LOCK SWITCH ^ POWER DOOR LOCKS - SELF ACTIVATE OR INOPERATIVE WHEN VEHICLE IS WET ^ REMOTE KEYLESS ENTRY - INOPERATIVE WHEN VEHICLE IS WET LIGHT TRUCK: 1996-98 ECONOLINE ISSUE Power door locks self activate, are inoperative, or remote keyless entry may be inoperative when vehicle is or has been wet. Water leaks onto the rear door power lock switch. This may be caused by: ^ Low torque on the door glass nuts ^ Door glass butyl rope seal off location ^ Porosity in sealant between the door seal C-channel-to-door sheet metal ^ Water entering inside the door from the hinges or check strap ACTION Repair leak and/or install water shield. Refer to the following Service Procedure for details. NOTE IF THE POWER LOCKS/REMOTE KEYLESS ENTRY ARE INOPERATIVE OR SELF-ACTIVATING AT THE TIME OF REPAIR, APPLICABILITY OF THIS TSB MAY BE CONFIRMED BY DISCONNECTING THE REAR DOOR SWITCH AND RETESTING. IF THE POWER LOCKS FUNCTION NORMALLY, THIS TSB WILL CORRECT THE CONCERN. SERVICE PROCEDURE Remove the interior trim halo moulding and door trim panel from the right rear door by referring to the procedures in the 1998 Econoline Workshop Manual, Pages 501-05-11 to 13. Perform the following Rear Door Glass, Door Seal C-Channel, and Door Hinges And Check Strap leak tests and repair procedures. NOTE VEHICLE MAY SELF-LOCK DURING WATER TEST. BE SURE KEYS ARE ACCESSIBLE. REAR DOOR GLASS Using water hose, direct water around the edge of the right rear door. Inspect for water leaks. If the door glass leaks, retighten nuts to 2.5 N.m (22 lb-in). If retightening the glass nuts does not stop the leak, replace the Rear Door Glass Module (F6UZ-15420A034-AA). DOOR SEAL C-CHANNEL Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 98-18-3 > Sep > 98 > Power Door Locks/Keyless Entry Inoperative When Wet > Page 10543 Inspect for gaps and holes in the factory applied sealer along the outboard side of the C-channel (Figure 1) (weatherstrip is pulled out of C-channel in Figure 1). Using a water bottle, force water into any hole to see if a leak occurs, allowing water to exit the opposite side of the C-channel. Adjust hose to spray pattern and direct water across the rear end of the roof and at the top of the door. Inspect for water leaks. If leaks are found using either test, reseal the entire length of each side of the C-channel to the door sheet metal using clear silicone sealant. DOOR HINGES AND CHECK STRAP Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 98-18-3 > Sep > 98 > Power Door Locks/Keyless Entry Inoperative When Wet > Page 10544 The hinges and check strap are not sealed and leaks are always expected. Install a Water Shield (XC2Z-15402A08-AA) to the door sheet metal (Figure 2). Route the switch wiring and connector under the bottom edge of the water shield (Figure 3). Be careful the water shield is not pulled loose by the wiring. PART NUMBER PART NAME XC2Z-15402A08-AA Water Shield F6UZ-15420A34-AA Rear Door Glass Module OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981803A Inspect For Water Leaks 1.3 Hrs. And Perform Repairs DEALER CODING CONDITION BASIC PART NO. CODE 14017 07 OASIS CODES: 110000, 112000, 205000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Specifications Window Track: Specifications Rear Glass Channel Bolt ..................................................................................................................... .............................................. 7-11 Nm (62-97 Lb-In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Recalls: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard Technical Service Bulletin # 98B34 Date: 990201 Campaign - Windshields Not Marked With AS1 Standard 98B34 OWNER NOTIFICATION PROGRAM Certain 1998 and 1999 Contours, Mystiques, Econoline Vans, and Ranger Trucks for Windshield AS1 Marking in Certain States. ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Recalls: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10556 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Recalls: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10557 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE: Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Recalls: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10558 NOTE: A handling allowance in lieu of parts markup may be claimed since the kit involved in this program is being supplied at no charge. See Attachment II. Attachment II - Labor and Parts Information LABOR ALLOWANCES To claim handling allowance on no-cost parts kit use the table: PARTS REQUIREMENTS Parts Ordering Information One glass etching kit will be direct shipped to dealers that have affected vehicles assigned to them. Each kit can etch (repair) up to 24 vehicles. Additional kits can be ordered from the Recall Hotline by calling 1-800-325-5621. DEALER PRICE The etching kit is being shipped at no charge. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 98B34 ^ Labor Operation: (see above) See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information SERVICE KIT NUMBER: XC25-19562-AA PREPARATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Recalls: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10559 NOTE: THIS KIT CAN BE USED ON UP TO 24 VEHICLES. RETAIN BRUSHES AND ETCHING CREAM UNTIL ALL STENCILS HAVE BEEN USED OR ALL VEHICLES HAVE BEEN COMPLETED. 1. Wear rubber or neoprene gloves and safety glasses. 2. Perform work in a well-ventilated area. 3. Use drop cloth or equivalent to protect hood and leaf screen from accidental drips/spillage of etching cream. CAUTION: Failure to allow windshield to reach from room temperature will affect transfer of stencil and could neutralize etching cream. 4. Allow windshield to reach room temperature (approximately 70° F). CAUTION: Moisture or windshield will neutralize etching cream. 5. Clean and dry outside surface of windshield, in area around trademark. APPLICATION OF STENCIL 1. Remove the white backing sheet from the frosted AS1, blue field stencil. 2. Position AS1 stencil on windshield as follows: ^ Select proper location for AS1 stencil from examples shown in Figure 1. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Recalls: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10560 ^ Place stencil on outside surface of windshield with blue (tacky) side touching windshield. See figure 2. 3. With smooth, even strokes, firmly rub over entire blue area of stencil. See Figure 3. Rub across stencil, then from top to bottom of stencil. DO NOT DIG INTO THE STENCIL. The entire blue field of the stencil will transfer from the sheet to the windshield. (During this process you will see the sheet turning to clear as the stencil transfers.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Recalls: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10561 4. Slowly peel back clear top sheet. See Figure 4. The AS1 lettering and surrounding blue field should remain on windshield. If the entire blue field did not transfer to the windshield, remove the blue field with luke warm water. Make sure the windshield is completely dry and at room temperature (approximately 70°F), then return to Step 1 of the "APPLICATION OF STENCIL." APPLICATION OF ETCHING CREAM 1. Shake/stir etching cream thoroughly. WARNING: DO NOT GET ETCHING CREAM OUTSIDE BLUE FIELD OF THE STENCIL, AS DAMAGE TO THE WINDSHIELD WILL OCCUR. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Recalls: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10562 2. Using brush, cover AS1 lettering with a thick layer of etching cream. See Figure 5. Use 2-3 vertical and 2-3 horizontal strokes to ensure complete coverage of the AS1 letters. 3. Leave etching cream on windshield for ONE (1) MINUTE ONLY. The AS1 lettering will blur if etching cream is left on the windshield longer than one (1) minute. 4. Wash off etching cream with a damp cloth or paper towel and luke warm water. 5. After all traces of etching cream have been washed away, clean windshield with glass cleaner to remove any remaining stencil pieces. CLEAN UP 1. Continue to wear protective gear during clean-up. 2. Clean brushes with luke warm water. 3. Dispose of unused or empty etching cream container in accordance with state and local regulations after all stencils have been used. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Recalls: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10563 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Recalls: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10564 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: Customer Interest Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 10570 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: All Technical Service Bulletins Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 10576 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard Technical Service Bulletin # 98B34 Date: 990201 Campaign - Windshields Not Marked With AS1 Standard 98B34 OWNER NOTIFICATION PROGRAM Certain 1998 and 1999 Contours, Mystiques, Econoline Vans, and Ranger Trucks for Windshield AS1 Marking in Certain States. ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10581 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10582 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE: Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10583 NOTE: A handling allowance in lieu of parts markup may be claimed since the kit involved in this program is being supplied at no charge. See Attachment II. Attachment II - Labor and Parts Information LABOR ALLOWANCES To claim handling allowance on no-cost parts kit use the table: PARTS REQUIREMENTS Parts Ordering Information One glass etching kit will be direct shipped to dealers that have affected vehicles assigned to them. Each kit can etch (repair) up to 24 vehicles. Additional kits can be ordered from the Recall Hotline by calling 1-800-325-5621. DEALER PRICE The etching kit is being shipped at no charge. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 98B34 ^ Labor Operation: (see above) See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information SERVICE KIT NUMBER: XC25-19562-AA PREPARATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10584 NOTE: THIS KIT CAN BE USED ON UP TO 24 VEHICLES. RETAIN BRUSHES AND ETCHING CREAM UNTIL ALL STENCILS HAVE BEEN USED OR ALL VEHICLES HAVE BEEN COMPLETED. 1. Wear rubber or neoprene gloves and safety glasses. 2. Perform work in a well-ventilated area. 3. Use drop cloth or equivalent to protect hood and leaf screen from accidental drips/spillage of etching cream. CAUTION: Failure to allow windshield to reach from room temperature will affect transfer of stencil and could neutralize etching cream. 4. Allow windshield to reach room temperature (approximately 70° F). CAUTION: Moisture or windshield will neutralize etching cream. 5. Clean and dry outside surface of windshield, in area around trademark. APPLICATION OF STENCIL 1. Remove the white backing sheet from the frosted AS1, blue field stencil. 2. Position AS1 stencil on windshield as follows: ^ Select proper location for AS1 stencil from examples shown in Figure 1. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10585 ^ Place stencil on outside surface of windshield with blue (tacky) side touching windshield. See figure 2. 3. With smooth, even strokes, firmly rub over entire blue area of stencil. See Figure 3. Rub across stencil, then from top to bottom of stencil. DO NOT DIG INTO THE STENCIL. The entire blue field of the stencil will transfer from the sheet to the windshield. (During this process you will see the sheet turning to clear as the stencil transfers.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10586 4. Slowly peel back clear top sheet. See Figure 4. The AS1 lettering and surrounding blue field should remain on windshield. If the entire blue field did not transfer to the windshield, remove the blue field with luke warm water. Make sure the windshield is completely dry and at room temperature (approximately 70°F), then return to Step 1 of the "APPLICATION OF STENCIL." APPLICATION OF ETCHING CREAM 1. Shake/stir etching cream thoroughly. WARNING: DO NOT GET ETCHING CREAM OUTSIDE BLUE FIELD OF THE STENCIL, AS DAMAGE TO THE WINDSHIELD WILL OCCUR. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10587 2. Using brush, cover AS1 lettering with a thick layer of etching cream. See Figure 5. Use 2-3 vertical and 2-3 horizontal strokes to ensure complete coverage of the AS1 letters. 3. Leave etching cream on windshield for ONE (1) MINUTE ONLY. The AS1 lettering will blur if etching cream is left on the windshield longer than one (1) minute. 4. Wash off etching cream with a damp cloth or paper towel and luke warm water. 5. After all traces of etching cream have been washed away, clean windshield with glass cleaner to remove any remaining stencil pieces. CLEAN UP 1. Continue to wear protective gear during clean-up. 2. Clean brushes with luke warm water. 3. Dispose of unused or empty etching cream container in accordance with state and local regulations after all stencils have been used. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10588 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10589 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: All Technical Service Bulletins Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 10595 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard Technical Service Bulletin # 98B34 Date: 990201 Campaign - Windshields Not Marked With AS1 Standard 98B34 OWNER NOTIFICATION PROGRAM Certain 1998 and 1999 Contours, Mystiques, Econoline Vans, and Ranger Trucks for Windshield AS1 Marking in Certain States. ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10601 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10602 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE: Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Enter claims using DWE. See ACESII Manual, Sections 5 & 6. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10603 NOTE: A handling allowance in lieu of parts markup may be claimed since the kit involved in this program is being supplied at no charge. See Attachment II. Attachment II - Labor and Parts Information LABOR ALLOWANCES To claim handling allowance on no-cost parts kit use the table: PARTS REQUIREMENTS Parts Ordering Information One glass etching kit will be direct shipped to dealers that have affected vehicles assigned to them. Each kit can etch (repair) up to 24 vehicles. Additional kits can be ordered from the Recall Hotline by calling 1-800-325-5621. DEALER PRICE The etching kit is being shipped at no charge. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 98B34 ^ Labor Operation: (see above) See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information SERVICE KIT NUMBER: XC25-19562-AA PREPARATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10604 NOTE: THIS KIT CAN BE USED ON UP TO 24 VEHICLES. RETAIN BRUSHES AND ETCHING CREAM UNTIL ALL STENCILS HAVE BEEN USED OR ALL VEHICLES HAVE BEEN COMPLETED. 1. Wear rubber or neoprene gloves and safety glasses. 2. Perform work in a well-ventilated area. 3. Use drop cloth or equivalent to protect hood and leaf screen from accidental drips/spillage of etching cream. CAUTION: Failure to allow windshield to reach from room temperature will affect transfer of stencil and could neutralize etching cream. 4. Allow windshield to reach room temperature (approximately 70° F). CAUTION: Moisture or windshield will neutralize etching cream. 5. Clean and dry outside surface of windshield, in area around trademark. APPLICATION OF STENCIL 1. Remove the white backing sheet from the frosted AS1, blue field stencil. 2. Position AS1 stencil on windshield as follows: ^ Select proper location for AS1 stencil from examples shown in Figure 1. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10605 ^ Place stencil on outside surface of windshield with blue (tacky) side touching windshield. See figure 2. 3. With smooth, even strokes, firmly rub over entire blue area of stencil. See Figure 3. Rub across stencil, then from top to bottom of stencil. DO NOT DIG INTO THE STENCIL. The entire blue field of the stencil will transfer from the sheet to the windshield. (During this process you will see the sheet turning to clear as the stencil transfers.) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10606 4. Slowly peel back clear top sheet. See Figure 4. The AS1 lettering and surrounding blue field should remain on windshield. If the entire blue field did not transfer to the windshield, remove the blue field with luke warm water. Make sure the windshield is completely dry and at room temperature (approximately 70°F), then return to Step 1 of the "APPLICATION OF STENCIL." APPLICATION OF ETCHING CREAM 1. Shake/stir etching cream thoroughly. WARNING: DO NOT GET ETCHING CREAM OUTSIDE BLUE FIELD OF THE STENCIL, AS DAMAGE TO THE WINDSHIELD WILL OCCUR. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10607 2. Using brush, cover AS1 lettering with a thick layer of etching cream. See Figure 5. Use 2-3 vertical and 2-3 horizontal strokes to ensure complete coverage of the AS1 letters. 3. Leave etching cream on windshield for ONE (1) MINUTE ONLY. The AS1 lettering will blur if etching cream is left on the windshield longer than one (1) minute. 4. Wash off etching cream with a damp cloth or paper towel and luke warm water. 5. After all traces of etching cream have been washed away, clean windshield with glass cleaner to remove any remaining stencil pieces. CLEAN UP 1. Continue to wear protective gear during clean-up. 2. Clean brushes with luke warm water. 3. Dispose of unused or empty etching cream container in accordance with state and local regulations after all stencils have been used. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10608 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 98B34 > Feb > 99 > Campaign - Windshields Not Marked With AS1 Standard > Page 10609 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10610 Windshield: Service and Repair Interior Auto Glass Cut-Out Knife Kit Special Tool(s) REMOVAL 1. Remove the windshield wiper pivot arms. 2. Remove the cowl top vent panel. 3. Drill out the rivets, and remove the windshield glass stops. 4. Remove the inside rear view mirror. 5. Remove (pull off) the RH and LH A-pillar mouldings. 6. Lower the front portion of the roof trim panel. 7. Lubricate the urethane sealant with ECL-784 lubricant (10:1 ratio of water to soap), to aid the Interior Glass Cut-Out Knife Kit when cutting the urethane sealant. 8. Insert the Interior Glass Cut-Out Knife into the urethane sealant at the upper center of the vehicle interior, and work toward the bottom corners. WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING THE HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE. CAUTION: To prevent damage to the windshield header seal, turn the blade so that the flat side is against the pinch weld. 9. Insert the Interior Glass Cut-Out Knife into the bottom center of the urethane sealant on the vehicle exterior, and work toward the corners. NOTE: Support the windshield glass, to prevent the glass from dropping, before cutting the bottom edge of the urethane sealant. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10611 10. Carefully remove the windshield glass from the vehicle. CAUTION: Removing the glass requires more than one technician. 11. Remove the windshield header seal. 12. Trim the remaining urethane on the pinch weld to within the specification. - The old urethane must be smooth and free of cuts and contamination. INSTALLATION 1. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that could cause glass damage. 2. Apply Urethane Body Primer WSB-M2G23C (black) to any exposed metal on the pinch weld. - Do not apply the primer to the existing urethane bead. - Let the primer dry for a minimum of 6-10 minutes before proceeding. 3. If re-installing the same windshield glass, remove all remaining traces of urethane sealant. 4. Install the windshield header seal on the windshield glass. 5. Properly align the windshield glass to the body, mark the windshield glass, and remove the windshield glass from the vehicle. 1 Place the windshield glass in the opening, and center it from top to bottom and side to side with about equal clearance on all sides. 2 Make alignment marks on each of the four sides of the windshield glass. 3 Remove the windshield glass from the vehicle, and place it inside up. 6. Clean the inside of the windshield glass with an alcohol-free cleaner. 7. Apply Urethane Glass Primer Wipe WSB-M5B280-C2 (red) to the entire inside perimeter of the windshield glass. Wipe off immediately after each application. NOTE: Apply with deliberate strokes, making sure not to overlap the applied area. 8. Apply Urethane Glass Primer WSB-M2G314-B (black) to the entire inside perimeter of the windshield glass. Allow a minimum of 5 minutes drying time. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10612 9. Apply an 11-mm (0.43-inch) wide bead of Urethane High Viscosity Adhesive WSB-M2G316-B to the entire primed area of the windshield glass. NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane sealant. 10. Position the windshield glass on the vehicle pinch weld, aligning it with the marks. CAUTION: After replacing the urethane-installed glass, the vehicle must not be driven until the urethane has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the urethane can adversely affect the strength of the urethane sealant bond. NOTE: Before installing the windshield glass, open the windows to prevent the windshield glass from being pushed out by air pressure if a door is closed. 11. Position the windshield glass stops on the vehicle. Make sure the windshield glass is aligned and rivet the stops in position, using a 385974-S rivet. 12. Wipe off any excess urethane sealant and apply a 6-mm (0.23-inch) bead of Pumpable Foam Dam ESB-M46309-A between the windshield header seal and the urethane sealant. 13. Fill the cavities between both the LH and RH sides of the windshield header seal and the sheet metal, using RTV Sealer ESB-M4G92-A for a total length of 50 mm (2 inches) from the base of the A-pillars. 14. Install the inside rear view mirror. 15. Install the roof trim panel. 16. Install (push on) the LH and RH A-pillar mouldings. 17. Install the cowl top vent panel. 18. Install the windshield wiper pivot arms. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations Windshield Washer Control Module: Locations Wiper Control Module And Bracket Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations > Page 10618 Windshield Washer Control Module: Service and Repair REMOVAL 1. Remove the engine cover. 2. Remove the wiper module. 1 Disconnect the electrical connector. 2 Push the detent tabs on the wiper control module through the holes in the mounting bracket and slide the module off the bracket. 3 Remove the wiper control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Instrument Panel Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10622 Wiper Control Module And Bracket The Wiper Control Module is located behind center side of the instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10623 Wiper Control Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10624 Wiper Control Module: Service and Repair REMOVAL 1. Remove the engine cover. 2. Remove the wiper module. 1 Disconnect the electrical connector. 2 Push the detent tabs on the wiper control module through the holes in the mounting bracket and slide the module off the bracket. 3 Remove the wiper control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 10629 Windshield Washer Switch: Diagrams Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 10630 Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Windshield Washer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10633 Windshield Washer Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10634 Windshield Washer Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10635 Windshield Washer Switch: Component Tests and General Diagnostics Terminals Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10636 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10637 1. Measure the resistance between the multi-function switch terminals. - If the resistances are as specified, the multi-function switch is OK. Return the multi-function switch to the vehicle. Test the system for normal operation. - If the resistances are not as specified, replace the multi-function switch. Test the system for normal operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 10638 Windshield Washer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 4. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 10639 5. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10643 Wiper Switch: Diagrams Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10644 Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10645 Wiper Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. - Ignition. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis Wiper Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10648 Wiper Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10649 Wiper Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10650 Wiper Switch: Pinpoint Tests Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10651 C1 Part 2 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10652 Part 3 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10653 Wiper Switch: Component Tests and General Diagnostics Terminals Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10654 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10655 1. Measure the resistance between the multi-function switch terminals. - If the resistances are as specified, the multi-function switch is OK. Return the multi-function switch to the vehicle. Test the system for normal operation. - If the resistances are not as specified, replace the multi-function switch. Test the system for normal operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 10656 Wiper Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 4. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 10657 5. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations Windshield Washer Control Module: Locations Wiper Control Module And Bracket Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations > Page 10661 Windshield Washer Control Module: Service and Repair REMOVAL 1. Remove the engine cover. 2. Remove the wiper module. 1 Disconnect the electrical connector. 2 Push the detent tabs on the wiper control module through the holes in the mounting bracket and slide the module off the bracket. 3 Remove the wiper control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation Windshield Washer Pump: Description and Operation To engage the windshield washer pump, push the knob at the end of the multi-function switch toward the steering column tube. When the multi-function switch is in the OFF or INT position, the windshield wipers will run in LOW while the knob is pushed in. When the washer knob is released, the washer will stop immediately, but the windshield wipers will continue to run for two or three sweeps, then return to their previously set mode. Washer engagement does not affect windshield wiper operation when the multi-function switch is in the LOW or HIGH position. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation > Page 10665 Windshield Washer Pump: Service and Repair REMOVAL 1. Raise and support the hood. 2. Remove the battery. 3. Remove the battery tray. 1 Remove the bolts. 2 Remove the battery tray. 4. Remove the washer pump and reservoir. 1 Remove the nut. 2 Remove the bolt. 3 Disconnect the filler hose. 4 Disconnect the electrical connector. 5 Detach the wiring harness locator from the washer pump and reservoir. 6 Disconnect the windshield washer hose. 7 Remove the washer pump and reservoir. NOTE: Windshield washer fluid must be collected in a container after the windshield washer hose is disconnected. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation > Page 10666 5. Remove the washer pump from the reservoir. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation > Page 10667 1. To install, reverse the removal procedure. - Fill the windshield washer reservoir with windshield washer fluid. CAUTION: Do not make electrical connection prior to filling the windshield washer reservoir. Do not operate the windshield washer pump prior to filling the windshield washer reservoir. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications Windshield Washer Reservoir: Specifications Windshield Wiper Reservoir Bolt ....................................................................................................................................................... 3-5 Nm (27-44 Lb-In) Windshield Wiper Reservoir Nut ........................................................................................................................................................ 3-5 Nm (27-44 Lb-In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 10671 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Raise and support the hood. 2. Remove the battery. 3. Remove the battery tray. 1 Remove the bolts. 2 Remove the battery tray. 4. Remove the washer pump and reservoir. 1 Remove the nut. 2 Remove the bolt. 3 Disconnect the filler hose. 4 Disconnect the electrical connector. 5 Detach the wiring harness locator from the washer pump and reservoir. 6 Disconnect the windshield washer hose. 7 Remove the washer pump and reservoir. NOTE: Windshield washer fluid must be collected in a container after the windshield washer hose is disconnected. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 10672 5. Remove the washer pump from the reservoir. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 10673 1. To install, reverse the removal procedure. - Fill the windshield washer reservoir with windshield washer fluid. CAUTION: Do not make electrical connection prior to filling the windshield washer reservoir. Do not operate the windshield washer pump prior to filling the windshield washer reservoir. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 10677 Windshield Washer Switch: Diagrams Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 10678 Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Windshield Washer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10681 Windshield Washer Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10682 Windshield Washer Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10683 Windshield Washer Switch: Component Tests and General Diagnostics Terminals Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10684 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10685 1. Measure the resistance between the multi-function switch terminals. - If the resistances are as specified, the multi-function switch is OK. Return the multi-function switch to the vehicle. Test the system for normal operation. - If the resistances are not as specified, replace the multi-function switch. Test the system for normal operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 10686 Windshield Washer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 4. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 10687 5. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications Wiper Arm: Specifications Center of Wiper Blade to Cowl Top Vent Panel RH ....................................................................................................................................................... ................................. 67.1-91.3 mm (2.64-3.59 in) LH ........................................................................ ................................................................................................................ 52.8-77.2 mm (2.08-3.04 in) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 10691 Wiper Arm: Adjustments 1. Cycle and park the windshield wipers. 2. Verify that the distance between the center of the RH windshield wiper blade and the cowl top vent panel is within specification. 3. Verify that the distance between the center of the LH windshield wiper blade and the cowl top vent panel is within specification. 4. If the distance is not within specification, remove the windshield wiper pivot arm that is not within specification and reposition it to specification. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 10692 Wiper Arm: Service and Repair REMOVAL NOTE: The windshield wiper pivot arm can be removed at any point in the wiper sweep without the use of tools. 1. Release the pivot arm locking lever. 1 Carefully raise the windshield wiper blade away from the windshield glass until it stops. 2 Pull the locking lever away from the windshield wiper pivot arm. 2. Lift the windshield wiper pivot arm from the windshield wiper mounting arm and pivot shaft. INSTALLATION 1. To install, reverse the removal procedure. Adjust the windshield wiper pivot arm. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Specifications Wiper Blade: Specifications Center of Wiper Blade to Cowl Top Vent Panel RH ....................................................................................................................................................... ................................. 67.1-91.3 mm (2.64-3.59 in) LH ........................................................................ ................................................................................................................ 52.8-77.2 mm (2.08-3.04 in) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Specifications > Page 10696 Wiper Blade: Adjustments 1. Cycle and park the windshield wipers. 2. Verify that the distance between the center of the RH windshield wiper blade and the cowl top vent panel is within specification. 3. Verify that the distance between the center of the LH windshield wiper blade and the cowl top vent panel is within specification. 4. If the distance is not within specification, remove the windshield wiper pivot arm that is not within specification and reposition it to specification. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Instrument Panel Views Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10700 Wiper Control Module And Bracket The Wiper Control Module is located behind center side of the instrument panel. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10701 Wiper Control Module Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10702 Wiper Control Module: Service and Repair REMOVAL 1. Remove the engine cover. 2. Remove the wiper module. 1 Disconnect the electrical connector. 2 Push the detent tabs on the wiper control module through the holes in the mounting bracket and slide the module off the bracket. 3 Remove the wiper control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications Wiper Motor: Specifications Windshield Wiper Motor Bolts .......................................................................................................................................................... 7-10 Nm (62-89 Lb-In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 10706 Windshield Wiper Motor Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 10707 Wiper Motor: Service and Repair REMOVAL 1. Remove the windshield wiper pivot arms. 2. Raise and support the hood. 3. Remove the cowl top vent panels 4. Disconnect the windshield wiper mounting arm and pivot shaft. 1 Remove the access cover from the dash panel. 2 Remove the retaining clip. 3 Disconnect the windshield wiper mounting arm and pivot shaft from the windshield wiper motor. 5. Remove the windshield wiper motor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the windshield wiper motor. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 10708 1. Install the mounting arm and pivot shaft retaining Clip on the windshield wiper mounting arm and pivot shaft. 2. Install the windshield wiper motor. 1 Position the windshield wiper motor in the dash panel. 2 Install the bolts. 3 Connect the electrical connector. 3. Connect the windshield wiper mounting arm and pivot shaft. 1 Press upward on the windshield wiper mounting arm and pivot shaft after it is aligned with the windshield wiper motor. 2 Install the access cover in the dash panel. 4. Install the cowl top vent panels. 5. Install the windshield wiper pivot arms. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications Wiper Motor Linkage: Specifications Windshield Wiper Mounting Arm and Pivot Shaft Screws ............................................................................................................... 7-10 Nm (62-89 Lb-In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications > Page 10712 Wiper Motor Linkage: Service and Repair REMOVAL 1. Remove the windshield wiper pivot arms. NOTE: The windshield wiper mounting arm and pivot shaft is replaced as an assembly. 2. Remove the cowl top vent panels. 3. Disconnect the windshield wiper mounting arm and pivot shaft. 1 Remove the access cover from the dash panel. 2 Remove the retaining clip. 3 Disconnect the windshield wiper mounting arm and pivot shaft from the windshield wiper motor. 4. Remove the windshield wiper mounting arm and pivot shaft. 1 Remove the screws. 2 Remove the windshield wiper mounting arm and pivot shaft. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications > Page 10713 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Specifications Wiper Pivot: Specifications Windshield Wiper Mounting Arm and Pivot Shaft Screws ................................................................................................................ 7-10 Nm (62-89 Lb-In) Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Specifications > Page 10717 Wiper Pivot: Service and Repair REMOVAL 1. Remove the windshield wiper pivot arms. NOTE: The windshield wiper mounting arm and pivot shaft is replaced as an assembly. 2. Remove the cowl top vent panels. 3. Disconnect the windshield wiper mounting arm and pivot shaft. 1 Remove the access cover from the dash panel. 2 Remove the retaining clip. 3 Disconnect the windshield wiper mounting arm and pivot shaft from the windshield wiper motor. 4. Remove the windshield wiper mounting arm and pivot shaft. 1 Remove the screws. 2 Remove the windshield wiper mounting arm and pivot shaft. INSTALLATION Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Specifications > Page 10718 1. To install, reverse the removal procedure. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10722 Wiper Switch: Diagrams Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10723 Multi_Function Switch Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10724 Wiper Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: - Turn signal. - Hazard flasher. - Windshield wiper/washer. - Rear wiper/washer. - Headlamp dimmer/flash-to-pass. - Ignition. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis Wiper Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10727 Wiper Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged multi-function switch - Blown fuse(s) - Damaged ignition switch - Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10728 Wiper Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10729 Wiper Switch: Pinpoint Tests Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10730 C1 Part 2 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10731 Part 3 Of 3 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10732 Wiper Switch: Component Tests and General Diagnostics Terminals Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10733 Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10734 1. Measure the resistance between the multi-function switch terminals. - If the resistances are as specified, the multi-function switch is OK. Return the multi-function switch to the vehicle. Test the system for normal operation. - If the resistances are not as specified, replace the multi-function switch. Test the system for normal operation. Ford Econoline E350 1 Ton Workshop Manual (V10-6.8L VIN S (1998)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 10735 Wiper Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. NOTE: The steering wheel is removed for clarity. 4. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. (3) Remove the upper steering column shroud.
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